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SERVICE MANUAL AHE-450-DE2 - Aqua

1. Page 99 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 8 Clean Ignition Electrodes and Flame Sensor Electrode Tips Figure E8 J 1 Ignition electrodes A Polish away any carbon deposits that may have baked onto the metal tips of the ignition electrodes with a course sponge 2 Flame Sensor A For light dirt dust and or carbon deposits simply wipe off the flame sensor with a soft cloth B Should heavy carbon deposits be present completely remove the flame sensor from the photo disc and clean with brake cleaner Page 100 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 9 Replace The Fuel Nozzle ignition Electrodes N Fuel Nozzle Eu Diesel Burner e Head Fuel Nozzle Fuel Nozzle Manifold Hex 1 Use a 3 4 in wrench to hold the fuel nozzle manifold hex while loosening the fuel nozzle with a 5 8 in wrench and remove NOTE Be sure to use care when handling the new fuel nozzle Oils and or small dust or dirt particles from your hands may plug the nozzle s small orifice A partially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner 2 When replacing the fuel nozzle be sure to tighten the nozzle loosen it a 1 4 turn and then firmly retighten This will estab lish a seated fit and
2. Ignition lt Coil Ignition Cable Brown Wire Brown Wire to Diesel Burner Yellow Wire to Diesel Burner Page 72 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SECTION 10 DIESEL BURNER COMPONENTS Diesel Burner Controller The diesel burner controller operates all the compo nents of the diesel burner head and safely shuts the heater OFF in the event of an overheat flameout and low voltage condition It also receives diesel burner operation status signals from the flame sen sor VDC control thermostat and VDC high limit thermostat Component Test The following conditions must exist prior to per forming the diesel burner controller circuit tests on the following page If one of the conditions below does not exist please contact our technical support department at 1 800 685 4298 for additional assis tance Condition 1 A battery voltage level between 11 5 to 14 0 volts DC must be present at the diesel burner controller during all testing It may be necessary to perform a voltage check to ensure that this condition exists To perform the voltage check locate the diesel burner controller s B plug and insert the probes of a DC voltmeter into the B 4 and B 2 loca tions Condition 2 A voltage level of between 11 5 to 14 0 volts must be present at the diesel ON OFF switch circuit of the diesel burner controller during all testing It ma
3. E WT Aqua Hot HYDRONIC HEATING SYSTEM 490 DE AHE 450 DE2 SERVICE MANUAL 2009 Aqua Hot Heating Systems Inc Page 2 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S Table of Contents Section 1 Introduction to the Aqua Hot 450 DE OGC olg maen Page 6 7 Danger Warning Caution and Note Box Deimtons se Page 6 Section 2 Aqua Hot Hydronic Heating System Overview CRIS ALI el un ie Re UE Page 8 ep cio NR t ee Page 9 COMPONEN OVO VOW sco edidi Mtr von EE Ei Page 9 11 Aqua Hot Operational Flow Chart ss e Page 12 Antifreeze amp Water Heating solution Page 13 14 Section 3 Interior Switch Panel DIGSePDUrLTet WIE sus LR acido eue usce quit uud eid ducum ere ere iD ni Page 15 Electric Klemen WIUCTI uode ecudedudexuidecudacidece dani dece taxa Page 15 ENGING PreENnCal SMIC WEE Page 15 PIT LADO Merc Page 16 Section 4 Exhaust System Requirements Exhaust oystem KeEguUrEMeEN ee Page 17 Section 5 Aqua Hot 450 DE Components Nghe ghee cies ei EE Page 18 mieu ecce Page 9 20 Go a io ie e le EE Page 20 21 AUC Hok CMI Thermostat clases Ga asses cele nmt den Has aE ec nement Page 22 DCS o Wi Ve TRI e EE Page 23 Low Temperature Cut Off Thermostat Page 24 25 Sa cle EE ee eet nae ee nee eee ee ee ere Page 25 26 Regele en eludet itu ieu iM E Mme Page 27 28 CCUM RUMP kE Z oodd eee ees cna Econo a Page 28 30 Se al gee ee een ee ne oue Ed
4. GRAS by the FDA should be utilized Because of the significant impact various types of antifreeze can have on a Hydronic heating system including the level of safety provided it has been recognized that there is a need to provide an explanation regarding two additional promi nent types of antifreeze coolant available The following information should be utilized as an educational means of ensuring that the proper type of propylene glycol based anti freeze is selected RV amp Marine Antifreeze These types of propylene glycol based antifreeze products are formulated specifically for winterizing applications only Although RV amp Marine antifreeze is often Generally Recognized as Safe by the FDA it should never be used in the Aqua Hot s Hydronic Heating System This type of anti freeze 1s not formulated to transfer heat which 1s essential to the heating system s functionality and does not contain rust inhibitors Please note however that RV amp Marine anti freeze can be utilized to winterize the Aqua Hot s domestic water heating system Automotive Antifreeze Coolant These types of propylene glycol based antifreeze products are formulated specifically to protect automotive engines against corrosion freezing temperatures and overheating They also have excellent heat transfer and thermal conduc 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 450 DE OVERVIEW
5. 3 Remove the defective interlock switch from the Aqua Hot 4 Install the replacement interlock switch onto the Aqua Hot ensuring that the locking tabs snap into place 5 Connect the Aqua Hot s wires to the replacement inter lock switch with yellow wire 24 connected to the ter minal labeled NO and yellow wire 25 connected to the terminal labeled COM NOTE If the interlock switch s wires are reversed the in terlock switch will only allow the diesel burner to operate when the access cover is removed and the button on the switch is released Fic ure d Interlock a Switch Button Locking Tab Connect L Connect Wire 24 sad vt Wire 25 9 COM Page 18 Fluid Level Sensor The fluid level sensor monitors the level of antifreeze and water heating solution within the Aqua Hot s boiler tank to ensure that an adequate volume exists Troubleshoot the fluid level sensor if one of the following conditions has occurred e The diesel burner and or electric heating element fails to operate e The Aqua Hot fails to operate and the Low Tank Level Cutoff indicator light on the electronic controller is illuminated Troubleshooting 1 Verify that the Aqua Hot s boiler tank is full of the anti freeze and water heating solution 2 Verify that the wire connector is securely plugged into the fluid level sensor and secured with the attached clip 3 V
6. 4 Place the opposite end of the hose into an adequate supply of FDA approved GRAS RV Antifreeze and turn on the demand water pump 5 Open and close all interior and exterior water faucets one at a time until only pure RV Antifreeze is present Perform this procedure for both the hot and cold faucets 6 Turn off Demand Water pump and remove the hose and re connect the domestic water demand pump s suction line to the fresh water storage tank WARNING An FDA approved GRAS rated winterization antifreeze must be used YOU CANNOT BLOW DOMESTIC WATER COIL OUT WITH AIR TO WINTERIZE AQUA HOT De Winterizing the Domestic Water Heating System For de winterization completely fill the fresh water storage tank Turn on demand water pump and open and close all interior and exterior water faucets one at a time until only clear water is present visible Reference Figure F1 If disinfecting the potable water system after de winterizing be sure to follow RVIA s Instructions for Disinfection of Potable Water Systems on Recreation Vehicles These instructions can be obtained by contacting the Recreational Vehicle Industry Association at 703 620 6003 www rvia com or writing to them at the following address visiting them online at Recreation Vehicle Industry Association 1896 Preston White Drive P O Box 2999 Reston VA 20195 0999 q LL RV Fresh Antifreeze Arrows indicate directional flow of
7. Fuel Pressure Regulator Fuel Solenoid Page 65 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 10 DIESEL BURNER COMPONENTS Fuel Pump Replacement Procedure NOTE To perform the following procedure it will be nec essary to remove the diesel burner Follow the section on detaching and reattaching the diesel burner section 9 of this manual Locate and disconnect the C Plug harness wires that connect to the flame sensor and the fuel solenoid Also disconnect the ignition cables from the igni tion electrodes Remove the retaining clip that secures the photo disc in place Gently lift the photo disc so that it releases from the nozzle stand and the ignition elec trodes Loosen the supply and return banjo bolts to remove the fuel supply and return pipes from the fuel pump Also disconnect the high pressure fuel pipe from both the fuel pump and the nozzle stand Discard the high pressure fuel pipe gasket rings and banjo bolts as replacements are provided in the new fuel pump kit Remove the four nozzle stand plate screws that se cure the nozzle stand plate in place Remove the nozzle stand plate by pulling on the nozzle stand until the plate releases from the cast aluminum blower casing Remove the two pump mounting screws that secure the fuel pump in place Turn the nozzle stand plate over and remove the snap ring from the fuel pump shaft using snap ring pliers
8. 5 F or higher the Motor 2 will not operate Only when the coolant temperature has dropped below 160 5 F and the VDC VAC Control Thermostat is call ing for heat will the Motor 2 begin to operate After approximately 10 25 se conds the Fuel Solenoid Valve 6 opens and fuel is sprayed into the Combustion Chamber 11 through the Fuel Nozzle 9 Operational Flow Chart After approximately 10 25 se conds the Fuel Solenoid Valve 6 opens and fuel is sprayed into the Combustion Chamber 11 through the Fuel Nozzle 9 Once the ignited air fuel mixture FLAME is observed by the Flame Sensor 13 the Ignition Coil 3 will automatically switch OFF The combustion process now continues to operate unassisted The combustion process will con tinue to operate in this manner until one of the following occurs A The VDC VAC Control Thermostat which senses cool ant temperature reaches the pre set temperature of approximately 190 5 F NOTE If process A occurs the Aqua Hot Heating Status Light on the Electronic Controller will go OFF B the Aqua Hot s Diesel Burn er Switch is turned OFF NOTE If process B occurs the Diesel Burner switch s Indicator Light on the Switch Panel will go OFF along with the Heating Status and Diesel Burner Status lights on the Electronic Control ler SECTION 8 DIESEL BURNER Once the heater switches OFF ther
9. Stir Pump Circulation Pump 73 The stir pump circulates the antifreeze and water heating solution within the Aqua Hot s boiler tank in order to ensure even heating of the solution To accomplish this the stir pump draws the solution from the bottom of the tank and immediately deposits it back into the top of the tank Troubleshoot the stir pump if the following condition has occurred e There is a lack of hot domestic water e Pump 3 indicator light illuminates red Troubleshooting NOTE In order for the stir pump to operate the diesel burner switch must be on and the indicator light for the Low Temp Cutoff Status on the electronic controller must be extinguished 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS Removing the mounting bracket from the replacement pump and the defective pump NOTE Verify the Electronic Controller Proper Jumper Pin formation Reference Section Electronic Controller for the proper jumper pin formation 1 Verify that the Pump 3 indicator light on the elec tronic controller is illuminated If the indicator light is not illuminated check the follow ing A Verify that the diesel burner Status Light is Illumi nated indicating the switch is on B Verify that the Low Temp Cutoff Status indicator light on the electronic controller is not illuminated If the diesel burner switch is on
10. 0 Water Storage domestic water Ben Tank 2 Was c Demand o Pump j TE To Cold Water Faucets Domestic Cold Water INLET Domestic Hot Water OUTLET To Hot Water Faucets Page 106 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX G FILLING DRAINING THE AQUA HOT WITH HEATING SOLUTION WARNING Only propylene glycol based boiler type antifreeze deemed GRAS Generally Recognized as Safe by the FDA shall be used in the Aqua Hot s hydronic heating system Failure to use the above specified antifreeze type could result in serious injury or death CAUTION Ensure that the overflow tube is connected from the Aqua Hot s expansion tank connection to the expansion tank s bottom connection and from the expansion tank s top con nection through the overflow tube hole in the motor home s bay floor prior to beginning this antifreeze and water heating solution fill procedure Failure to do so could result in an antifreeze spill in the motor home s bay Reference Figure 30 Filling The Aqua Hot Heating System with Boiler Antifreeze In order to provide the best freeze protection boil over pro tection and anti corrosion and rust protection a 50 50 mix ture of GRAS approved propylene glycol boiler antifreeze and water is recommended Reference Section 1 Antifreeze and Water Heating Solution for addition
11. and the engine preheat pump is operating The system is also functioning correctly when the engine preheat switch is off and the engine preheat pump is not op erating Page 40 SECTION 7 ELECTRONIC CONTROLLER INDICATOR LIGHTS If the red light illuminates when the pump should be func tioning then there is either an issue with the wiring or the engine preheat pump NOTE The Low Temp Cut Off light must be illuminated for the Engine Preheat pump to be activated Pump 1 This indicator light shows the status of the circulation pump that controls the fluid for Heating Zones 1 and 5 by illumi nating green for on red for fault and by turning off when the system is off The system is functioning properly if the coach thermostat is calling for heat the pump is operating and the light is green The system is also functioning properly if the pump and light are off and the thermostat is not calling for heat If the light is red under any condition then there is either an issue with the wiring or the circulation pump Pump 2 This indicator light shows the status of the circulation pump that controls the fluid for Heating Zones 2 3 and 4 by illuminating green for on red for fault and by turning off when the system 1s off The system is functioning properly if the motor home interi or thermostat is calling for heat the circulation pump is ac tive and the indicator light is green The system is
12. automatically begin reheating the antifreeze and water heating solution when the Boiler Tank drops below 160 F The cooled antifreeze and water heating solution is returned to the Boiler Tank to be reheated Heat is transferred into the Zone calling for heat Diesel Burner Switch Turned ON Diesel Burner heat source selected by Diesel Burner switch Diesel Burner fires into the Combustion Chamber which heats the antifreeze and water heating solution in the Boiler Tank 10 20 Minutes The Circulation Pump activates for the Zone which called for heat The heated antifreeze and water heating solution is trans ported throughout the plumbing lines in that zone NOTE The Circula tion Pumps and Heat Exchangers will not operate until the Boiler Tank reaches a minimum of 150 F Antifreeze and water heating solution moves through the Heat Exchangers in the Zone calling for heat 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Boiler Tank heats to 190 F Zone Thermostat calls for heat Heat Exchanger fans activate Electric Element Switch Turned ON Electric Heating Element heat source selected by Electric Element switch Electric Heating Element activates which heats the antifreeze and water heating solution in the Boiler Tank 1 2 Hours The Engine Preheat switch on the Interior Switch Panel is activated Heat is tr
13. ing valve Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Turn the motor home s water pump off 2 Drain the water pressure by opening the faucets and al lowing the water to drain 3 Disconnect the motor home s water lines from the tem pering valve assembly 4 Disconnect the pex pipe and fittings from the tempering valve assembly 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS 5 Remove the pressure relief valve assembly from the tempering valve assembly as the tempering valve cannot be removed from the Aqua Hot with the pressure relief valve still attached 6 Using a back up wrench unscrew the tempering valve from the Aqua Hot CAUTION A back up wrench must be used for loosening and removing the tempering valve from the Aqua Hot Failure to use the back up wrench will cause the copper domestic water coil to twist and kink which will render the domestic water feature unusable 7 Remove the brass fittings from the defective tempering valve 8 Install the brass fittings onto the replacement tempering valve NOTE Be sure to wrap Teflon tape around the threads of the brass fittings to prevent domestic water from leaking 9 Install the replacement tempering valve onto the Aqua Hot using a bac
14. ter heating solution to determine when it is at operating tem perature and when it requires heat The Aqua Hot is consid ered to be at operating temperature between 158 F and 190 F Troubleshoot the control thermostat if one of the following conditions has occurred e There is a lack of hot domestic water and interior heat e The heating Status light does not illuminate on the elec tronic controller when the Aqua Hot is below 158 F e Excessive Blue or white smoke is expelled from the ex haust Troubleshooting 1 Turn the diesel burner and electric element switches on the interior switch panel on and check the electronic controller to ensure that the Electric Heating Element Status and Diesel Burner Status indicator lights are illuminated 2 Verify that the Heating Status indicator light on the electronic controller is illuminated as it should be when ever the Aqua Hot is below the operating temperature range of 158 F 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS If the Heating Status indicator light is not illuminated check the following A Verify that the temperature of the boiler tank has fallen below the 158 F minimum operating temper ature by checking with a digital thermometer B Disconnect the control thermostat s wires from their connections and using an ohmmeter check for continuity If there is no co
15. then using a voltmeter check the wires on the wiring harness for 12 volts of DC pow er If 12 volts of DC power are present at the wiring harness follow the instructions in this section to replace the circulation pump If the indicator light illuminates red complete the fol lowing A Disconnect the circulation pump s wires If the indicator light turns green with the circulation pump disconnected follow the instructions in this section to replace the circulation pump If the indicator light remains red with the circulation pump disconnected check the wiring for damage If no damage is found follow the instructions in this manual to replace the electronic controller NOTE The circulation pump can be tested by con necting it to an external 12 Volt DC source to verify that the pump is defective Replacement Procedure FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the potential for hot coolant be sure the heater is adequately cooled 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS 10 11 12 13 Drain the antifreeze and water heating solution from the Aqua Hot s boiler t
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17. 450 D Hydronic Heating System Service Manual Rev A SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 5 Remove the Diesel Burner from the Aqua Hot Figure 36a Figure 36b 1 The Diesel Burner is secured to the Aqua Hot with two nuts that can be loosened and swung out of the way by using a 10mm socket wrench with a 10 inch long exten sion 2 Carefully pull the Diesel Burner away from the Aqua Hot 4 to 5 inches before rotating the burner and then remove Page 50 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Reattaching the Diesel Burner to the Aqua Hot CAUTION When reattaching the diesel burner be sure to properly align the diesel burner before tightening the eye bolt nuts Also visually inspect all of the rubber grommets on the top and bottom of the diesel burner s cast aluminum blower casing to ensure they are in place DO NOT over tighten the eye bolt nuts Torque specifi cations are approx 20 40 in lbs An improper alignment and or over tightening of the eye bolt nuts can cause damage to the diesel burner s cast aluminum blower casing Step 1 Reattaching the Diesel Burner to the Aqua Hot Figure 37a 1 The Diesel Burner is secured to the Aqua Hot with two eye bolt nuts that can be swung into place after the diesel burner has been properly aligned and set in place 2 The eye bolt nuts ca
18. 88 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 2 Adjust the Fuel pressure to 145 PSI Figure C11 Fuel Pressure Gauge ee d av ml C eil increase Fuel Pump e Ey Pressure Regulator decrease Screw Adjustment 1 Once the fuel solenoid has been activated and the fuel pressure gauge is registering a pressure the fuel pressure can be adjusted To increase the fuel pressure turn the pressure adjustment screw clock wise and to reduce the fuel pressure turn the pressure adjustment screw counter clockwise NOTE Ifthe fuel pressure cannot be adjusted refer to the fuel pump section in section Of this manu al for troubleshooting tips Page 89 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX D EXTREME COLD WEATHER OPERATION WARNING When storing the Motor home Not winterizing the Aqua Hot when freezing temperatures are present will result in serious damage to the Aqua Hot s Domestic Water Heating System Also be sure to use an FDA approved GRAS rated antifreeze for winterization NOTE The Aqua Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized 120 Volt A C Electric Heating Element Please note that the 120 Volt AC
19. A EARE AAEE AEE NAREN Page 43 Diesel Burner Operational Flow Chart ss Page 44 Diesel Burner Operational Overview s nsunsnnsnnnnrsnnrrrnrrnrrnrrnnnnrnnrnrrnrrnrrnrrnernenne Page 45 47 Section 9 Detaching and Reattaching the Diesel Burner Detaching the Diesel Burner nan0nnannnnanonnnnonnnnnnnnnnnrennnrrnrnrrnenrrnennrnrnnrnrrnenrrnrnnne Page 48 51 Reattaching the UDiesebBumer Page 52 53 Section 10 Diesel Burner Components and Repair Information Diesel Burner Component Overview eseessesssessesseenn nennen nnne enean nnns nenas Page 54 Mise C A Page 55 58 MCAS SOS OR Page 59 60 ONUN leCIrOQRS m Page 61 62 mulio ovra or rS Page 62 63 miele Em Page 64 miii dian oem EET Page 65 67 zii tee T TT T Page 68 70 ONON 6 err Page 71 72 ail dell E Page 73 74 Page 4 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Table of Contents section 11 Troubleshooting If the Aqua Hot is Black SMOKING Rs Page 75 If the Aqua Hot is Blue White Smoking a annannannannanoannnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnrenrrnrrnnnne Page 76 If one of the Aqua Hot s Heating Zones will not get hot Page 77 If there is a lack of domestic continuous hot water Page 78 I th re 1s antilTee 7e ln e WE Page 9 80 Appendix A Wiring DIAGFalli 5 552 oi nn Ge po eei ane eee iex ee eoe et Page 81 Appendix
20. AC access cover Remove the two wires secured to the defective electric heating element by releasing the screw terminals Using a 1 1 2 inch socket remove the defective electric heating element from the Aqua Hot s boiler tank Install the replacement 1650 watt electric heating ele ment into the boiler tank ensuring that the up lettering on the element is installed in the up position Connect the wires removed from the defective electric heating element to the replacement electric heating ele ment and tighten the screw terminals Reinstall the AC access cover Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution Electric Heating Element AC Access Cover Aqua Hot 450 D with the AC Access Cover Removed Page 34 AC Relay The AC relay is an electrical device where the DC circuit from the electronic controller determines whether the AC power is permitted to flow to the electric heating element This allows the electronic controller to switch the electric heating element on and off in conjunction with the interior switch panel and control thermostat even though the electric heating element is on a separate circuit Troubleshoot the AC relay if the following condition has occurred e The electric heating element fails to operate Troubleshooting 1 Disconnect the AC power source to the motorhome unplugging from shore power or shutting off the gener ator 2 Tu
21. Approx 15mA Low voltage cutoff threshold 10 0V Low voltage lockout delay Approx 5 minutes Input Load Currents Zone thermostats each Approx 4mA Diesel Burner switchen Approx 12mA Electric Element switch Approx 4mA Engine Preheat switch Approx 4mA Low level cutoff switch Approx 10mA Control Thermostat sseeeeeeeeeeee Approx 8mA Low temperature cutoff switch Approx 5mA Output Current Capacity Zone TANS CACM area decor 2 0A max Circulation pumps each 2 0A max Engine preheat pump 0osssosooseeseeeeeeeeeeeeseeeeee 2 0A max Eeer 500mA max B4 burner Webasto power 6 0A max B1 burner master control 2 0A max C1 C7 burner thermostat control 1 0A max Page 36 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Electronic Controller Features Secondary 12 Volt DC Battery Connection The electronic controller is equipped with two 12 Volt DC power source connections which allow for a secondary 12 Volt DC battery connection This 12 Volt DC battery con nection is a product safety feature that should be utilized whenever the Aqua Hot s main
22. C 1 location to the C 7 location Failure to do so will result in an overheating condition during normal operation Replacement Procedure 1 Remove both the B plug and the C plug from the diesel burner controller Gently pry away each side of the diesel burner controller bracket from the die sel burner controller s locking posts with a flat head screw driver Once the locking posts have been released pull on the diesel burner controller to re move it from the diesel burner head Slide the new diesel burner controller into the diesel burner controller bracket Push down on the diesel burner controller until the locking posts snap into the bracket slots Reconnect the B plug and the C plug Be sure to install the diesel burner controller with it s C plug and B plug ports facing downward Failure to do so will result in moisture collecting in the ports and potential damage to the diesel burner controller s internal circuitry Figure 58b Bracket Slot Locking Post Diesel Burner Controller Controller Mounting Bracket Diesel Burner Controller 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Page 74 SECTION 11 TROUBLESHOOTING IF THE AQUA HOT IS BLACK SMOKING 1 Things to check before opening up heater 1 Low Voltage Fire up generator plug coach into shore power 2 Damaged or Restricted exhaust pipe nspect exhaust pipe for damage 2 Access cover must
23. D Hydronic Heating System Service Manual Rev A e APPENDIX G FILLING DRAINING THE AQUA HOT WITH HEATING SOLUTION WARNING Only propylene glycol based boiler type antifreeze deemed GRAS Generally Recognized as Safe by the FDA shall be used in the Aqua Hot s Hydronic heating system Failure to use the above specified antifreeze type could result in serious injury or death CAUTION Ensure that the overflow tube is connected from the Aqua Hot s expansion tank connection to the expansion tank s bottom connection and from the expansion tank s top con nection through the overflow tube hole in the motor home s bay floor prior to beginning this antifreeze and water heating solution fill procedure Failure to do so could result in an antifreeze spill in the motor home s bay Reference Figure 30 In order to provide the best freeze protection boil over pro tection and anti corrosion and rust protection a 50 50 mix ture of GRAS approved propylene glycol boiler antifreeze and water is recommended Reference Section 1 Antifreeze and Water Heating Solution for additional information regarding the antifreeze and water heating solution Be sure to use a GRAS boiler type pro pylene glycol based antifreeze rather than an RV and Marine antifreeze or an automotive antifreeze coolant If assistance is needed in selecting an appropriate antifreeze please contact the Aqua Hot Heating Systems Pro
24. IF THERE Is ANTIFREEZE LEAKING NOTE To find an antifreeze leak the system must be Hot up to operating temperature Or pressurized to 15PSI Inspect the following components on the Aqua Hot Heating System for Leaks 1 On the Front Side of Aqua Hot 1 Fluid Level Sensor a It might be necessary to cut away some of the insulation around the fluid level sensor to locate the leak 2 Control Thermostat b It might be necessary to cut away some of the insulation around the Control Thermostat to lo cate the leak 3 Drain Valve and Hose going to the drain valve 4 Electric element 5 Circulation Stir pump c Hoses d Tank ports It might be necessary to cut away some of the insulation around the tank ports to locate the leak e Pump 6 Burn Chamber Leak a If Antifreeze 1s running out of the tip of the exhaust pipe remove the burner and combustion chamber and inspect inside the burn chamber for leaks Page 79 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A P SECTION 11 TROUBLESHOOTING IF THERE Is ANTIFREEZE LEAKING CONTINUED 2 On the Top Side of Aqua Hot 1 Expansion Tank Connection a Cracked expansion tank tubing b Loose air release valve c Brass hose barb fitting defective or loose 2 Return Ports A Defective fitting B Leaking fitting 3 On the Rear Side of Aqua Hot 1 Copper Pipes a The copper pipes come out of the tank so they are possibl
25. Using a 7 8 socket unscrew the control thermostat from the Aqua Hot s boiler tank Control Thermostat SECTION 5 AQUA HOT COMPONENTS Wrap the threads of the replacement control thermostat with Teflon tape Screw the replacement control thermostat into the port on the Aqua Hot s boiler tank and tighten securely with a 7 8 socket Connect the replacement control thermostat s wires in the same configuration as the removed control thermo stat s wires Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution Test the Aqua Hot for normal operation Page 21 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A AC High Limit Thermostat The AC high limit thermostat serves as a safety measure in the event that the electric heating element continues to oper ate after the maximum operating temperature is reached The high limit thermostat allows the current for the heating element to pass through it until the boiler tank reaches a tem perature of 215 F Should this temperature be reached the high limit thermostat blocks the current to the element which prevents it from continuing to provide heat to the boil er tank Troubleshoot the AC high limit thermostat if the following condition has occurred e The electric heating element fails to operate Troubleshooting 1 Disconnect all power supplies 2 Remove the AC access cover 3 Verify that the boiler t
26. a jumper wire on me IPT plus between the tion has occurred pins corresponding to the room thermostat operating the circulation pump that is not operating Refer e The circulation pump is not operating and the Low ence the wiring diagram in Appendix A This will Temp Cutoff Status indicator light is illuminated on the bypass the room thermostat electronic controller e The Zone Pump indicator light illuminates red on the When the Heating Zone Status indicator light electronic controller illuminates on the electronic controller the corre sponding Pump 1 and or Pump 2 indicator Troubleshooting light should illuminate as well 1 Verify that the Low Temp Cutoff Status indicator B With the jumper wire installed check the indicator light on the electronic controller is illuminated as it will light corresponding to the pump not operating be whenever the boiler tank is at operating temperature and domestic hot water is not being used If the indicator light illuminates green complete the following Page 28 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A A Using a voltmeter check for 12 volts of DC power on the JP3 plug pins corresponding to the pump not operating If 12 volts of DC power are not present follow the instructions in this manual to replace the electronic controller B Disconnect the circulation pump s wires from the wiring harness
27. and the blower casing If the burner is assembled improperly the protection cap will not go on 4 Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its black and brown wires from the C plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed 5 Remove the three hex head screws that secure the motor and motor flange to the blower housing Re move the motor and flange assembly along with the clutch halves Disconnect the motor s black and brown wires from the C plug harness wires 6 Remove the four blower housing screws that secure the blower housing to the blower casing Remove the blower housing so that the combustion air blow er 1s exposed 7 Hold side B of the blower casing and loosen the retaining nut located in side A of the blower casing Remove the retaining nut steel drive gear and thick flat washer from the combustion air blower s shaft Lightly tap the threaded end of the shaft so that the combustion air blower can be easily removed from the blower casing Be sure to observe the placement of the three wash ers of the bearing kit To ensure proper tension the same order and direction of the dished surfaces of the washers must be followed when reassembling 8 With a pair of snap ring pliers remove the snap rings from both side A and s
28. avoid any leaks Be sure to reattach the diesel burner head prior to switching the heater ON Failure to do so may result in ignition of the diesel burner and serious bodily injury Page 101 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 10 Adjust Ignition Electrodes Electrode Adjustment Gauge Igniton Retaining metal tips Electrode re Ignition Photo Disc Electrodes Properly Positioned Ignition Clamp T VAE A TS I Electrode i Adjustment Gauge Cables i Electrical Insulators Fuel Nozzle Manifold 1 Using a 10mm socket slightly loosen the retaining clamp bolt 2 Place the electrode adjustment gauge on the nozzle manifold hex and insert the metal tips of the ignition electrodes into the appropriate notches of the electrode adjustment gauge 3 Using a 10 mm socket tighten the retaining clamp bolt Be sure not to over tighten the retaining clamp bolt when readjusting the ignition electrodes Over tightening the retaining clamp bolt will bend the retaining clamp and prevent the photo disc from floating freely Not allowing the photo disc to float freely will cause poor combustion and result in a smoky exhaust A bent retaining clamp can be re straightened with a punch and hammer Lay the clamp s beveled side down on a solid flat surface and align the thick end of the punch at dead center Tap the punch lightly unt
29. be removed to check the following Air Intake Closed off on the bottom of the burner is the air adjustment set at the half way point Broken Protection Cap Check cap for cracks or missing pieces Worn OUT Grommets run hands over grommets on top and bottom and feel for excessive air Burner not seated properly or Loose run hands along the seal of the burner and check for excessive air Air Intake Sleeve collapsed nA BW ND ra 3 Diesel Burner must be removed to check the following 1 Photo Disc Bent or Tight The photo disc must be loose so it will seal on the combustion chamber properly 2 Combustion Chamber Warped Melted Inspect for signs of warping melted aluminum 3 Bad Nozzle If nozzle is spraying poorly it must be replaced 4 Fuel Pressure not at 145 PSI Check fuel pressure with fuel pressure gauge 4 Diesel Burner must be torn down to check the following 1 Slow Motor Less Than 4500rpms at 12v aslow motor acts the same as low voltage Check motor rpm with an rpm tester under full load 2 Bearings are Worn Out Bearings should spin freely and sound smooth If they are starting to seize up they will slow the motor down 3 Impeller Fan Not Gapped Properly The impeller needs to be gapped at 3 5 thousands or tighten fan down until it rubs back it off 1 4 turn Page 75 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A P SECTION 11 TROUBLESHOOTI
30. follow the instructions in this section to replace the low temperature cutoff thermostat 2 If the light remains illuminated with the low temperature cutoff thermostat s wires discon nected verify that the jumper pins on the elec tronic controller are properly positioned Ref erence Section 7 for the proper pin jumper con figuration 3 If the jumper pins are properly positioned follow the instructions in this manual to replace the electronic controller Low Temperature Cut Off Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Page 24 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Locate the low temperature cutoff thermostat on the cold domestic water inlet pipe at the back of the Aqua Hot 3 Disconnect the defective low temperature cutoff thermo stats wires by separating the quick disconnect termi nals 4 Using a 5 8 wrench or socket remove the defective low temperature cutoff thermostat from the Aqua Hot 5 Install the replacement low temperature cutoff thermo stat tightening only to 15 in Ibs Do not overtighten 6 Connect the replacement low temperature cutoff ther mostat s wires in the same configuration as the removed thermostat s wires Valves Check Valve Check valves are instal
31. of DC power are present at the wiring har ness complete the following A Verify that the pump is operating by placing a hand on the pump to feel for vibrations If no vibrations are felt follow the instructions in this section to replace the stir pump SECTION 5 AQUA HOT COMPONENTS B Once it is determined that the pump is active verify that the pump is operating properly by checking both connected hoses for heat If both hoses are hot the pump is working properly If one hose is hot or neither hose is hot check the cold hose for a blockage If no blockage exists follow the instructions in this section to replace the stir pump Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the potential for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve 3 Disconnect the defective stir pump s wires by separating the quick disconnect terminals 4 Using constant tension pliers loosen and slide back the constant tension clamps securing the hoses to the stir pump 5 Remove the hoses from the defective stir pu
32. the Low Temp Cutoff Status indicator light is not illuminated and the stir pump is not operating follow the instruc tions in this manual to replace the electronic con troller Page 30 Check the color of the illuminated Pump 3 indicator light on the electronic controller If the indicator light is illuminated red the stir pump is experiencing a short therefore complete the following A Disconnect the stir pump s wires If the Pump 3 indicator light turns green when the stir pump is disconnected follow the instruc tions in this section to replace the stir pump If the Pump 3 indicator light remains red when the stir pump is disconnected check the wiring for damage If no damage is found follow the instruc tion in this manual to replace the electronic control ler If the indicator light is illuminated green complete the following A Using a voltmeter check for 12 Volts of DC power on the JP3 plug between pins 1 and 2 PUMP 3 and PUMP 3 on the electronic controller If 12 Volts of DC power are not present follow the instructions in this manual to replace the electronic controller Disconnect the stir pump s wires from the wiring har ness then using a voltmeter check the wires on the wiring harness for 12 Volts of DC power If 12 Volts of DC power are not present inspect and test the wires going from the electronic controller to the pump If 12 Volts
33. the electronic controller and the diesel burner controller s B Plug which is the diesel burner motor power wire Component Test 2 THERMO IND LT 83 Locate the diesel burner controller s C Plug and insert the probes of a DC voltmeter into the C 2 and the C 5 locations A Turn the diesel switch ON and verify both the diesel burner status light and the heating status lights are illuminated on the electronic controller If either light is not illuminated follow the trouble shooting guide for that particular component B Observe the voltage level If a normal voltage registers on the voltmeter and the motor is not operating inspect the C Plug Harness for loose or damaged wire connections If the C Plug harness and connections are in good condition but the motor is not operation the motor must be replaced Oo JP5 JP7 JP8 MIN 12V GND IND LT 1 20A Fast Blow Fuse sAqua Hot 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Verify the Electronic Controller is sending power to the diesel burner motor A Using a volt meter check for 12 Volt DC on the JP4 plug on the B4 pin red wire 3 If no power is present verify the electronic controller is receiving power from the batteries i Locate the main power terminals on the bottom of the electronic controller ii Using a volt Meter check for 12 Volt D C on the JP 8 terminal If no voltage is present v
34. the Air Swirler is warped the combustion chamber must be replace A Inspect the outer ring that the photo disc seats against for signs of warping B Inspect the back side of the Air Swirler for signs of warping between screws Page 97 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 6 Reinstall the Combustion Chamber CAUTION Failure to reinstall the combustion chamber will result in serious damage to the diesel burner Seam on stainless steel tube 1 Reinstall the combustion chamber into the Aqua Hot Please note the seam on the stainless steel tube must be in the up position Failure to do so could result in premature failure of the combustion chamber Page 98 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 7 Inspect Diesel Burner Figure E7 Fuel Nozzle A afl j j D Si E af M Photo Disc Inspect the following 5 Flame Sensor 1 Electrodes cracked damaged overheated purple color improperly adjusted melted wires dirty 2 Fuel Pump leaks 6 Rubber Grommets hard brittle 3 Photo disc rubber has been cut out warped right left bent 7 Broken or cracked Ears 4 Harness amp Ignition Coil Wires due to over tightening of eyebolts crack or bare wires Hard or brittle wires
35. 12 Volt DC power supply is connected to a battery disconnect switch This feature will NOTE If the optional power connection is used remove the jumper plate from the two power terminals JP5 and JP8 Optional connection to the sem mm m house battery disconnect Positive Power 1 rz In line Fuse NOTE Reference Appendix A for specific electronic controller wiring details Negative Ground Terminal Strips with Screw Type Fasteners The electronic controller uses terminal strips plugs that are equipped with screw type fasteners which are molded di rectly into the terminal strip plug itself This will ensure a positive mechanical connection between the electronic con troller and all wire harnesses attached to it SECTION 6 ELECTRONIC CONTROLLER ensure that the Aqua Hot will be protected in the event that the primary power is interrupted while the diesel burner is operating e g during a burn cycle This secondary 12 Volt DC battery connection will ensure completion of the re quired 3 minute purge cycle of the Aqua Hot s diesel burner Figure 22 der ET tum ale e zA XX eg enm B wal gt MA eg o mmm mmm mmm mmm mmm mm mmm wf ca 5 vis ot di apos ied Screws 2 per Plug eee eee eee eee Ce BAP de Wy 0909999 Page 37 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 6 ELECT
36. B Wire E e CC TT dE Page 82 83 Appendix C Fuel Pressure check and Adjustment Page 84 89 Appendix D Extreme Cold Weather Operation Page 90 91 Appendix E Aqua Hot Annual Maintenance eee eeeee eere eene Page 92 105 Appendix F Winterization Process ceelerlerlerlenieeie nee n annue n ana nnmnnn enn a na Page 106 Appendix G Filling Draining the Aqua Hot esses Page 107 110 Page 5 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A a SECTION 1 This service and parts manual is designed to aid trained and qualified service technicians with the process of troubleshooting and servicing the Aqua Hot 450 DE Hydronic heating system The Aqua Hot 450 DE heating system features a 12 Volt DC powered diesel burner and a 120 Volt AC 1650 Watt elec tric heating element These two heating sources are used in conjunction with an FDA approved GRAS Generally Recognized as Safe propylene glycol based boiler antifreeze and water heating solution in order to provide a continuous supply of domestic hot water interior fresh water tank heat ing independent interior zone heating and engine preheat ing Be sure to reference Figures 3 through 5 for a com plete component overview Pleas
37. Electric Heating Element is the Aqua Hot s secondary heat source for heating both the interior and or the domestic hot water during low heating de mand situations such as when moderate ambient temperatures exist and or when there is a low demand for domestic hot wa ter If the 120 Volt AC Electric Heating Element is not providing enough heat turn the Diesel Burner on in conjunction with the 120 Volt AC Electric Heating Element Diesel Electric Diesel Burner 1 Ifthe Diesel burner Fails to operate A Is the Diesel Fuel in the motor home winter fuel or summer fuel B Is the Diesel Fuel liquid or Jelled C Are the electrodes properly adjusted D When was the last time an Annual Service was performed Engine Preheat Page 90 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Front APPENDIX D EXTREME COLD WEATHER OPERATION If there is a lack of interior Heat Note The 120 Volt AC Electric Heating Element is the Aqua Hot s secondary heat source for heating both the interior and or the domestic hot water during low heat ing demand situations such as when moderate ambient temperatures exist and or when there is a low demand for domestic hot water If the ambient temperature is ex 1 Is the Diesel Burner activated 2 Is the Diesel Burner operating Properly 3 What is the antifreeze concentration inside of the Aqua Hot Boiler Tank 4 Was the heating sy
38. NG IF THE AQUA HOT is BLUE WHITE SMOKING 1 If The Heater Smokes on Start up Shut down a Fuel solenoid plunger worn out plastic metal in the way of plunger fuel solenoid intermittent b Nozzle Tower cracked poorly machined c Short cycling control t stat bad someone turned heater off on repeatedly d Return Fuel Check Valve heaters manufactured before 2001 2 If The Heater Smokes During The Burn Cycle a Electrodes out of adjustment b Air in the fuel system c Bad nozzle d Fuel pressure e Fuel Pump f Intermittent Ignition Coil Ifthe coil doesn t turn on the fuel sprays for 20 seconds before the photo eye shuts the fuel off Page 76 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A P SECTION 11 TROUBLESHOOTING IF ONE OF THE AQUA HOT HEATING ZONES WILL NOT GET HOT 1 General Problems A Q Diesel Electric not operating antifreeze cold Heater is Not up to operating Temperature antifreeze is cold Interior Zone Thermostat Not calling for heat Zone Circulation Pump Not Operating Heat Exchanger Fans Not Operating The Low Temp Cut Off status light is not illuminated on the Electronic Control Board The Electronic Control Board is wired wrong 1 e the fans for the bedroom come on but the pump for the living room comes on 2 If Fans and Pumps are Running A Stuck Check Valve B C Kinked Line No Antifreeze i
39. RONIC CONTROLLER Low Voltage Reset Feature button on the electronic controller use a thin straight non Whenever the Aqua Hot s DC power is interrupted for long metallic object to access the button through the faceplate or er than 5 minutes the low battery voltage fault red indica by turning off the diesel burner switch on the interior switch tor light on the electronic controller will illuminate Reset panel for approximately 30 seconds then turning the switch the electronic controller by pressing the low voltage reset back on Reset Button Electronic Controller Board Terminal Stnp Plug Q 0 Header d PMP x o SW ue T a y 23 im z E ax Sara 3 s 2 Eo a S o O E es S e I S LE 38 E at n 5 k E o LI Secondary Power Source 12 Volt DC Screw Terminal Primary Power Source 12 Volt DC Screw Terminal Ground Wire Screw Terminal Page 38 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 6 ELECTRONIC CONTROLLER Replacement Procedure bracket by unsnapping each corner A DANGERI A 6 Snap the replacement electronic controller into the FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR mounting bracket TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 7 Ensure that the pin jumpers are properly configured for Ensure that the Aqua Hot has been completely shut d
40. Remove the four blower housing screws that secure the blower housing to the blower casing Remove the blower housing so that the combustion air blower is exposed Spin the combustion air blower by hand Placing one of the clutch halves to the end of the shaft assists with the spinning of the bearings If the combustion air blower rotates smoothly with out any friction or noise the bearings are in proper working condition If the combustion air blower does not rotate smoothly and or produces noise the bearings are worn and must be replaced Replacement In order to perform the following procedure it is necessary to detach and reattach the diesel burner head Be sure to review the detaching and reattach ing section for detaching and reattaching instruc tions Locate and disconnect the C plug harness wires that connect to the flame sensor and fuel solenoid Also disconnect the ignition cables from the ignition electrodes Blower Housing Page 68 SECTION 10 DIESEL BURNER COMPONENTS 3 Remove the four nozzle stand plate screws that se cure the nozzle stand plate in place Remove the nozzle stand plate by pulling on the nozzle stand until the plate releases from the cast aluminum blower casing NOTE It is recommended to mark the internal components of the diesel burner prior to disassembling of the burner Make a mark between the motor flange and the blower hous ing and also between the blower housing
41. Remove the nylon drive gear and then the fuel pump Attach the new fuel pump to the nozzle stand plate with the two pump mounting screws Turn the noz zle stand plate over to install the nylon drive gear on the fuel pump s shaft and secure in place with the snap ring Dab the teeth of the nylon drive gear with white lithium grease Isoflex LDS 18 is recom mended Do not adjust the fuel pressure regulator of the new fuel pump as it has been factory preset 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Inspect the nylon drive gear s cavity inside the cast alumi num blower casting for fuel stains If fuel stains are present a replacement of the bearings and or the entire blower cas ing may be necessary Leaking fuel could cause bearing seizure resulting in potential damage to the internal bore bearing of the blower casing 10 11 12 I5 Fit the nozzle stand plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Install the grommets on the fuel return and supply banjo pipes and secure the pipes to the fuel pump with the new banjo bolts and gasket rings Failure to use the new gasket rings or the correct order placement could result in a fuel leak Reconnect the C plug harness violet and brown wires to the fuel solenoid s and electrical terminals Insert both the ignition cables into the rubber grom
42. SOLUTION 5 When refilling open the air release valve located on the expansion tank connection to release air pockets Refer ence Figure G2 Hold the valve open until all air is re leased Be sure the valve is closed when finished by hand tightening Look for the solution to enter the over flow tube attached to the expansion tank connection on top of the Aqua Hot 6 Close the drain valve Purging the System by Grounding the Zone Circulation Pump 1 Ensure that the boiler tank has been filled with the appropriate 50 50 mixture of antifreeze and water heating solution 2 Locate the heating zone circulation pumps Refer ence Figure G2 3 Take the circulation pump s blue negative wire and disconnect it from the connector of the oppos ing wire Reference Figure G3 4 Connect an alligator clip to the spade terminal on the circulation pump s blue negative wire and clip the opposite end of the cable to a ground source Page 108 NOTE The circulation pump will activate as soon as the pump is connected to a ground source therefore disconnect the alligator clip from the ground source during the antifreeze and water heating solution filling procedure Allow the circulation pump to operate for approxi mately 1 3 minutes in order to purge the corre sponding heating loop then remove the alligator clip from the ground source Open the drain valve and completely fill the Aqua Hot s boil
43. ainer the fuel pump must be replaced Prior to replacing the fuel pump be sure to inspect the screen filter in the supply inlet of the fuel pump for dirt particles Clean and or replace if necessary A plugged screen filter will restrict fuel from enter ing the fuel pump 7 If fuel does flow through the fuel pump when ran off an external source inspect the following in the motor home A Check the motor home fuel tank for fuel If the fuel level is below 1 4 the Aqua Hot diesel burner will not operate B Inspect the supply fuel line for kinks which would prohibit fuel flow C Inspect the supply fuel line for cuts which would cause the diesel burner to suck air D Inspect the fuel filter to make sure all fittings are tight including hose clamps Also make sure the fuel filter is tight E Inspect the Aqua Hot for loose or cracked fittings F Inspect the supply fuel system for loose hose clamps throughout G Inspect the fuel pick up tube in the tank for loose connection and pin holes in the pick up tube Fuel Pump Cleaning and Maintenance L 2 Check all fuel connections for tightness Check the screen filter located in the fuel supply inlet of the fuel pump for dirt particles Clean and or replace if necessary To adjust the fuel pressure refer to Appendix C Fuel pressure check and adjustment FUEL PUMP OVERVIEW Fuel Nozzle Air Relief Bore Fuel Supply Line Fuel Return Line
44. al information regarding the antifreeze and water heating solution Be sure to use a GRAS boiler type pro pylene glycol based antifreeze rather than an RV and Marine antifreeze or an automotive antifreeze coolant Figure G1 Figure G1 f d d M h LI troi SN 11 119 1 ys W Ww If assistance is needed in selecting an appropriate antifreeze please contact the Aqua Hot Heating Systems Product Appli cation Department at 1 800 685 4298 NOTE To Fill the Aqua Hot it is recommended to use a fluid transfer pump and pump the antifreeze into the Boiler Tank thru the drain valve on the Aqua Hot 1 Open the Aqua Hot s drain valve located at the front of the heater Reference Figure Gl 2 Connect a piece of 1 2 inch PEX type tubing to the drain valve This piece should be long enough to trans port the antifreeze and water heating solution from its source to the Aqua Hot 3 Connect the other end of the 1 2 inch PEX type tubing to the fluid transfer pump 4 Turn the fluid transfer pump on and fill the Aqua Hot completely with the 50 50 mixture of antifreeze and water heating solution This will take approximately five gallons look for the solution to enter the overflow tube attached to the expansion tank connection on top of the Aqua Hot Page 107 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX G FILLING DRAINING THE AQUA HOT WITH HEATING
45. also functioning properly if the circulation pump and indicator light are off and the thermostat is not calling for heat If the light is red under any condition there is either an issue with the wiring or the circulation pump Pump 3 Stir Pump This indicator light shows the status of the stir pump by illu minating green for on red for fault and by turning off when either the Low Temp Cut Off Status light is illuminated with 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A the Diesel Burner Switch on or the Diesel Burner Switch is turned off The system is functioning if the Stir Pump is operating when the Diesel Burner Status light is illuminated and the Low Temp Cut Off light is extinguished 1 e running hot water The system is also functioning properly if the stir pump and indicator light are off when the Diesel Burner Status light and the Low Temp Cut Off status lights are illuminated or the Diesel Burner Switch is turned off If the light is red under any condition then there is an issue with either the wiring or the stir pump Diesel Burner Status This indicator light shows the status of the diesel burner by illuminating green when the diesel burner is on red for fault and by turning off when the diesel burner switch is turned off If the diesel burner switch on the interior switch panel is in the on position then the indicator light should be illuminat ed green When the Die
46. ank s temperature is below 215 F 4 Locate the AC high limit thermostat and remove its wires 5 Using an ohmmeter check the thermostat for continuity If there is no continuity press the white reset button on the thermostat and re check for continuity If continuity 1s still not present after the reset button has been pressed follow the instructions in this section to replace the AC high limit thermostat A C High Limit Thermostat 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY Ensure that the Aqua Hot has been completely shut down and that all power supplies have been disconnect ed Remove the AC access cover If applicable remove the heat shrink insulation covering the wires and terminals on the defective high limit ther mostat Remove the two wires from the defective high limit thermostat by pulling firmly on the wires Using a 5 8 wrench or socket remove the defective high limit thermostat from the Aqua Hot s boiler tank Install the replacement high limit thermostat into the port on the Aqua Hot s boiler tank and finger tighten only 15 in Ibs Connect the wires removed from the defective high limit thermostat to the replacement high limit the
47. ank using the drain valve Disconnect the defective circulation pump s wires by separating the quick disconnect terminals Using constant tension pliers loosen and slide back the constant tension clamps securing the hoses to the circu lation pump Remove the hoses from the defective circulation pump For ease of replacement pump installation the defective circulation pump s mounting bracket should remain fas tened to the heater and only the pump should be re moved Therefore to detach the defective pump re move the three screws on the back of the attached mounting bracket Slide the defective pump out of the bracket and set aside The replacement pump will arrive complete with a mounting bracket however because the existing bracket remains mounted to the heater the new mounting brack et must be removed by detaching the three screws secur ing it to the replacement pump Slide the replacement pump into the existing mounting bracket and secure with the three screws previously re moved from the replacement pump Slide the hoses back onto the replacement pump and set the constant tension clamps back into place Reconnect the wires on the replacement pump to the wire harness on the heater by uniting the red quick disconnect terminals Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution Test the Aqua Hot for normal operation Page 29 n Circulation Pump
48. ansferred to the Engine Preheat System The engine s coolant is circulated through the Aqua Hot s internal Engine Preheat System where the heat from the Boiler Tank is transferred to the engine s coolant The antifreeze and water heating solution within the Boiler Tank is reheated as needed and contin ues warming the engine s coolant as it circulates through the Aqua Hot s internal Engine Preheat System A hot water faucet e g kitchen sink shower etc calls for hot water Heat is transferred to the Domestic Water System Continuous hot water is supplied to the faucet Page 12 Antifreeze and Water Heating Solution As the antifreeze type and mixture ratio is essential to the Aqua Hot s performance and ability to comply with reg ulations the following information is being supplied to understand various types of antifreeze the quality of wa ter necessary and the mixture ratio Aqua Hot Heating Systems Inc recommends CAMCO s Boiler Antifreeze 100 Antifreeze Types The following information addresses the necessary usage of a propylene glycol based boiler type antifreeze in the Aq ua Hot Propylene glycol is a safer alternative to the more toxic ethylene glycol antifreeze however as mandated by IAPMO International Association of Plumbing and Mechan ical Officials only those propylene glycol based boiler type antifreezes deemed Generally Recognized as Safe
49. anual Rev A Page 93 APPENDIX E AQUA HOT MAINTENANCE Aqua Hot Maintenance Procedure Step 4 Remove The Diesel Burner CAUTION Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to beginning this replacement procedure Figure E4a 1 Locate the Diesel Burner s Controller and dis 2 Using an 7 16 wrench loosen the nuts securing connect both plugs each fuel line to the Aqua Hot Figure E4d 3 The Diesel Burner is secured to the Aqua Hot with two nuts that can be loosened and swung out of the way by using a 10mm socket wrench with a 10 inch long extension Page 94 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Aqua Hot Maintenance Procedure Step 4 Remove The Diesel Burner continued Figure E4e l n Diesel Burner s white Thermostat Plug em 4 Carefully pull the Diesel Burner away from the Aqua Hot 4 to 5 inches before rotating the burner and then remove NOTE To remove the diesel burner it may be necessary to disconnect the control and h1 limit thermo stats from the diesel burner s white thermostat plug Page 95 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs Use caution when handling the combustion chamb
50. calibrated part and cannot be cleaned or serviced A replacement of the fuel nozzle is recommended annually 4 Turn ON the diesel switch for 5 seconds then turn it OFF This will activate the diesel burner s Fuel Nozzle Replacement Procedure prime cycle and flush the fuel system of any poten tial contaminants Perform this procedure twice 1 Use a 3 4 in wrench to hold the fuel nozzle stand hex while loosening the fuel nozzle with a 5 8 in 5 Test for normal operation wrench and remove Be sure to use care when handling the new fuel nozzle Oils and or small dust or dirt particles from your hands may plug the nozzle s small orifice A partially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner Figure 49 Ignition Electrodes Fuel Nozzte Diesel Burner Head Fuel Nozzle Fuel Nozzle Manifold Hex Page 63 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 10 DIESEL BURNER COMPONENTS Fuel Solenoid The fuel solenoid allows the flow of diesel fuel to the diesel burner s fuel nozzle If a long after smoking condition exists during the diesel burner s purge cycle the fuel solenoid valve kit may need to be replaced In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching instructions Fue
51. connect the Fuel Lines 1 Align the fuel lines on the diesel burner with the fittings on the Aqua Hot and using a 7 16 inch wrench tighten down both the supply and return fuel fittings CAUTION Be sure to remove the clamps off of the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to start ing the diesel burner or serious damage will occur to the diesel burner s fuel pump Step 14 Plug in the diesel burner s controller and mount ao a ac co 1 Locate the Diesel Burner s Controller and connect both plugs NOTE The Diesel Burner s Controller might have to be mounted onto the side of the diesel burner before the plugs are inserted into the control unit otherwise it might not be possible to mount the control unit Page 104 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S APPENDIX E AQUA HOT MAINTENANCE Step 15 Re Install the Aqua Hot Access Cover NOTE The access cover must be installed prior to operation as a safety switch exists which will prevent the Aqua Hot from operating whenever the access cover is not properly installed Aqua Hot 450 D el 2 n t bw Ps d A ar T E Si E y e An D RS ag ES EN M g De 9 Gb e T E Cover Fastener Access Cover 1 Reinstall the Aqua Hot s access cover 2 Securely tighten the three bolts securing the ac cess cover in place Step 15 Test for No
52. d to run monthly to keep it in good working order Fuel Filter 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Annual Maintenance A DANGER FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY To keep the Aqua Hot running smoothly it is recommended to have the diesel burner tuned up annually A tune up should consist of a new fuel nozzle and fuel filter along with a thorough cleaning of the combustion chamber To ensure maximum diesel burner performance always use the recom mended fuel nozzle and fuel filter when replacing these parts NOTE Be sure to use care when handling the fuel nozzle Oils and or small dust or dirt particles from the hands may plug the nozzle s small orifice A par tially plugged orifice will restrict fuel flow which will affect the combustion process of the diesel burner Fuel Nozzle Combustion Chamber The diesel burner has been removed tn this view to show the location of the combustion chamber for cleaning Page 92 APPENDIX E AQUA HOT MAINTENANCE Aqua Hot Maintenance Procedure 3 Replace fuel filter with proper replacement canister Note Before performing an annual maintenance it is recommended to test run NOTE It is recommended that the replacement fuel filter the Diesel Burner While te
53. duct Appli cation Department at 1 800 685 4298 TO DRAIN THE AQUA HOT 1 Connect a piece of 1 2 inch PEX type tubing or rubber hose to the drain valve This piece should be long enough to transport the antifreeze and water heating solution from the Aqua hot to a bucket 2 Open the Aqua Hot s drain valve located at the front of the heater Reference Figure G4 Note The Aqua Hot 450 holds approximate ly 5 gallons of the antifreeze and water heating solution Page 110 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Page 111 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A i Ny NW Aqua Hot HYDRONIC HEATING SYSTEM 450 DE SERVICE MANUAL m 8 Ge 15549 East Highway 52 Fort Lupton CO 80621 am SZ A Ua LA OT Toll free 800 685 4298 phone 303 659 8221 fax 303 857 7881 HEATING SYSTEMS INC www aquahot com
54. e 158 F the Aqua Hot is at operating temperature and requires no heat 3 Verify the Electronic Controller is sending 12 Volt DC to the A C Relay A Using a volt meter check pins 11 amp 12 AC REL and AC REL for 12 Volt D C on the JP3 plug If 12 Volts of DC power is not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller 4 If 12 Volts of DC power are present at the relay complete the following A Locate the AC wires connected to the AC relay pins 2 and 4 and remove the AC wires from the relay B Using an ohmmeter check the relay AC pins 2 and 4 for continuity If no continuity exists follow the instructions in this section to replace the AC relay 5 Verify that the electric heating element is receiving adequate AC power by completing the following A Remove the AC access cover B Plug the Coach into shore power turn generator on Page 33 C Using an AC voltmeter verify that 110 volts of AC power are present at the terminal block reference figure 20 If there is not 110 VAC present at the terminal block for the electric element there is a problem inside the motor home D Using a digital clamp meter verify the electric ele ment s amp draw is between 11 2 to 13 amps E Check the electric element
55. e experienced use this sequence of operating events KEY provided to understand each symbol shown Diesel Fuel Spray ama Combustion Air gt Exhaust Gases The particular component begins to operate LL The component is currently operating Diesel Burner Operation When the Diese switch is turned ON the Motor and Combustion Air Blower begin to operate This Combustion process is referred to as the prime cycle Air Blower e Motor ET NOTE The Motor and Combustion Air Blower will begin to operate only if the VDC VAC Control Thermostat is closed and calling for heat J Combustion Air The Fuel Pump builds up pressure against the Fue Solenoid Valve After approximately 10 25 seconds the Fuel Solenoid Valve opens and fuel is released into the Fuel Nozzle then sprayed into the Combustion Chamber Fuel Nozzle Fuel Solenoid Valve Combustion Diesel Fuel Chamber Fuel Pump Supply and Return Page 45 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 8 DIESEL BURNER Diesel Fuel Spray Combustion Air Exhaust Gases The particular component begins to operate mE The component is currently operating Diesel Burner Operation continued The gnition Coil produces a high voltage spark which is transferred across the gnition Electrodes The incoming air fuel mixture is then ignited creating combustion Igniti
56. e note that all Danger Warning Caution and Note box es appearing as needed throughout this manual must be reviewed and adhered to during any service procedure in order to avoid potential hazards which could result in injury product damage or property damage Should additional assistance be needed please contact the technical support department at 1 800 685 4298 Monday through Friday between the hours of 7 00 AM and 4 00 PM Mountain Standard Time Danger Warning Caution and Note Boxes Danger Warning Caution and Note boxes appear through out this manual as a means of alerting the service technician to important information A DANGER A INDICATES THAT PERSONAL INJURY IS LIKELY OR IMMINENT WARNING Indicates that serious damage to the heater will occur and personal injury is possible as well Indicates that damage to the heater is possible NOTE Indicates information that requires special atten tion by the service technician INTRODUCTION TO THE AQUA HoT 450 DE Understanding the Aqua Hot 450 DE s Major Systems The basis for the Aqua Hot heating system s functionality is the antifreeze and water heatng solution which is comprised of water that is distilled de ionized or soft as well as FDA approved GRAS propylene glycol based boiler antifreeze Through this solution s ability to maintain and transfer heat the Aqua Hot s three major systems the domestic water system
57. e points of antifreeze leaks Either where the brass fittings go into the tank or at the copper pipes where they go through the brass fittings Note If no leaks are found on the Aqua Hot it is possible that there is a leak within the motor home Check all Heat exchangers connections and tubing for leaks Page 80 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A P WIRING DIAGRAM APPENDIX A s pen M P94 SGA Zi o M 0591 OWA 0ZL m L I G 0SP OH enby 39 0S OH enby DESCH vor 104 wossou enbemmm git SR 008 1 NS SEI OYA ASUS NI SINS318AS ON i 20H enbyz e N g SD i r ST woo d osna mon D 1504 VOZ UWI HOIH 1 f em O OJ O 0 muU 1AN HOIH 18 82 Lo Oo H OI oe a JE duing i Dr e Nad JOZI A E euo7 dt Tom 459 eis nie 4 Lj q3a oz San NAG IZ vak EE ou 1V3H 33d i IHM Z Lj CAEN EUMD LB EE AE cz BAP ano I Lo o O RT oo X20 1831NI m Fe S E Q34 O N18 Z f i H il Nag L 2s o E zi aT RE Lj Ai IWISOW3HL muda H Ki i UWI HOIH n a ST ol 1 DE i HOT ao at mg zi nouina OU IVISOWMN3HI emer 3 x18 ri Gs i aa 1 610 91 H IVA OL SIM List DOA l O1 pes ZLs MO0S91 2vA OZCI 1N3W313 W YSTIONLNOD 9INOW19313 me ee me ee ee en ee men me eme ee ee meme me l A AlddnS 1MOd DGA ZL OL e
58. e to do so may result in serious bodily injury In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil Figure C8 Diesel Electric Engine Preheat 2 Turn the diesel burner switch to the on position A pressure will register on the fuel pressure gauge once the fuel solenoid opens after approx 10 20 seconds Page 87 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Adjusting Fuel Pressure Step 1 Follow the directions for Checking the Fuel Pressure in this section Figure C9 1 Using an external fuel source and rubber fuel line hook the Webasto burner supply and return fuel lines up to run off of the external fuel source WARNING A spark will appear across the ignition electrodes for a brief moment after the diesel burner has been activated DO NOT attempt to make any fuel pressure adjustments until the spark has disappeared Failure to do so may result in serious bodily injury In some installations it may be necessary to shine a light on the flame sensor to simulate a flame condition to shot of the ignition coil Figure C10 Diesel Electric Engine Preheat 2 Turn the diesel burner switch to the on position A pressure will register on the fuel pressure gauge once the fuel solenoid opens after approx 10 20 seconds Page
59. ead Be sure to review section 9 for detaching and reattaching the diesel burner instructions Bearing Test In order to perform the following procedure it is necessary to detach and reattach the diesel burner head Be sure to review the detaching and reattach ing section for detaching and reattaching instruc tions Locate and disconnect the C plug harness wires that connect to the flame sensor and fuel solenoid Also disconnect the ignition cables from the ignition electrodes Remove the four nozzle stand plate screws that se cure the nozzle stand plate in place Remove the nozzle stand plate by pulling on the nozzle stand until the plate releases from the cast aluminum blower casing Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its black and brown wires from the C plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed U U Protection p y Housing gt im Sd Bie b gt IIS TG LD 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A 5 6 T 8 Remove the three hex head screws that secure the motor and motor flange to the blower housing Re move the motor and flange assembly along with the clutch halves Disconnect the motor s black and brown wires from the C plug harness wires
60. eating Zone Heating Zone 2 1 Outlet Port Outlet Port AC Wiring Wiring Harness amp Harness Port Port AC Terminal Block VAC Access Panel Diesel Burner Diesel Burner pum Controller Combustion Air Sleeve Interlock Zone 2 Zone 1 Circulation Switch Circulation Pump Pump Mounting Tray TM Page 9 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 450 DE OVERVIEW Aqua Hot 450 DE Rear View capo nin a 9 ii i Domestic Cold Water Inlet Engine Preheat Inlet from engine Engine Preheat Outlet to engine Engine Preheat Circulation Pump Domestic Hot Water Outlet Gi 9 9 9 9 CG Tempering Valve Page 10 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 450 DE OVERVIEW Aqua Hot 450 DE Top View Heating Zone Inlet Ports Expansion Tank Connection AC Wiring Cable Clamp 9 WARNING 4 Heating Zone Outiet Ports 7 Wiring Harness Port 8 Diesel Fuel Inlet Outlet Ports Page 11 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 450 DE OVERVIEW AQUA HOT OPERATIONAL Heat Source is selected from the Interior Switch Panel FLOW CHART NOTE The Diesel Burner and or Electric Heating Element as switched ON will
61. ecure the fuel solenoid in place with the new flat washer and lock nut 4 Connect the C plug harness violet and brown wires to the fuel solenoid s and electrical terminals Retaining Clamp Ignition Cable Violet wire Brown wire Photo Disc Retaining Clip Fuel Solenosd Valve Cod Lock Nut Electrical Terminals kk Fuel Solenoid Shaft Fuel Solenoid Valve Kit SZ Fuel Solenoid Valve Coil Fuel Solenoid Valve Assembly Page 64 SECTION 10 DIESEL BURNER COMPONENTS Fuel Pump F The fuel pump draws diesel fuel from the vehicle s fuel tank and creates a preset pressure of 145 PSI which is required for proper fuel atomization Ref erence the illustration below for a basic overview and understanding of how the fuel pump functions uel Pump Testing Procedure Do not remove the diesel burner at this time Failure to do so may result in serious bodily injury Clamp off and remove the fuel return and fuel sup ply lines coming into the Aqua Hot unit Attach a short piece of fuel line to both the fuel re turn and fuel supply ports Submerse the opposite end of the temporary fuel supply line in a container of diesel fuel Place the opposite end of the temporary fuel return line in an empty container Turn the diesel switch ON to activate the diesel burner and wait ten seconds If fuel does not flow out of the return line into the empty cont
62. ement switch must also be activated in order for the engine preheat feature to function The engine preheat switch does not need to be activated for the motor aide feature to work and should be shut off when traveling Uua Hiot MYUORDONIC HEATING SYSTEM Electric Burner 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Element Preheat amp Page 15 SECTION 3 INTERIOR SWITCH PANEL Engine Electric Diesel Preheat Element Burner Switch Mount Location Switch Mount Location Switch Mount Location Pin2 PREHEAT Pin 3 ELECTRIC Pin2 DIESELO _Pin 4 Jump to Pin 2 Ping Jump to Pin2 _Pin 4 B3 INDIC Ping 86 INDIC _ Pin 6 __ Chassis Ground kel Engine Preheat Pin 6 Back of the Interior Switch Panel with the Switches Installed Page 16 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 4 EXHAUST SYSTEM REQUIREMENTS Because the Aqua Hot s exhaust is hot and must be kept away from any heat sensitive material the exhaust system should be checked to ensure that it continues to meet the following requirements e The exhaust must not be directed downward as a fire could result when parked in dry grassy areas e The exhaust must not terminate underneath the vehicle underneath an open able window or vent in the awning area of the motor home if applicable or near slide out areas The ex
63. engine preheat system and interior heating system are able to function effectively This antifreeze and water heating solution is contained within the Aqua Hot s boiler tank and is heated by the diesel burner when its operating criteria are met and or the electric heating element when its operating criteria are met In order for the diesel burner to be considered as a heating source by the Aqua Hot it must have an adequate fuel supply receive power from the elec tronic controller and be selected as a heating source from the interior switch panel In order for the electric heating ele ment to be considered as a heating source by the Aqua Hot it must receive power from either a generator or from shore power and be selected as a heating source from the interior switch panel Once the antifreeze and water heating solution achieves operating temperature as determined by the Aqua Hot s control thermostat the domestic water system the engine preheat system and the interior heating system are permitted to operate as needed Domestic Hot Water Priority System The Aqua Hot 450 is a Hot Water Priority System Mean ing that the Aqua Hot 450 cannot heat the interior of the motor home and produce continuous hot water simultane ously When Domestic Hot Water is being used the interior heating system will shut down until no more Domestic Hot Water is called for The domestic hot water priority system is responsible for providing hot wa
64. er it may be extremely hot and serious burns could result from touching a hot combustion chamber Heat Transfer Tabs T E i j hrs D kd ge M r2 m e 2 Ai ET D md up mt gt Le TL Jg ERE 2 Once the combustion chamber has been removed Use a long handled wire brush and brush the heat trans fer tabs to loosen soot deposits Failure to do so will reduce the Aqua Hot s heat transfer capabilities 1 Remove the combustion chamber by pulling it straight out approximately 16 inches NOTE If the heat transfer tabs are excessively sooty it may be necessary to vacuum the soot out of the heat transfer tabs If there is a minimal amount of soot it may be left in the heat transfer tabs and will be evacuated out the exhaust pipe upon start up of diesel burner Page 96 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 5 Clean and Inspect the Combustion Chamber and Heat Transfer Tabs Seam on stain less steel tube Back side of Air Swirler Outer ring that the photo disc seats against 3 Inspect the combustion chamber for damage or signs of warping 1 Inspect the combustion chamber for cracks appearing along the seam of the stainless steel tube A Ifthe crack is over 1 in length the combustion chamber must be replaced 2 Inspect the aluminum Air Swirler for signs of warping If any part of
65. er tank with additional antifreeze and wa ter heating solution Repeat steps 5 and 6 for both heating loops until all air has been completely bled from the entire heating system All air is bled from the heating system when both plumbing lines are free of air 10 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Once the systems have been purged disconnect the alligator clips from the ground source and the circu lation pump s wires Reconnect the pump s wires as originally configured Reference Figure G3 Check the Aqua Hot s expansion tank and top it off to the cold level mark with the 50 50 antifreeze and water mixture if necessary Ensure that each circulation pump s wiring has been returned to its original configuration Reference Figure G3 Wi Aqua Hot 450 D P e Ml e e g i gt E D Page 108 APPENDIX G FILLING DRAINING THE AQUA HOT WITH HEATING SOLUTION F E D o p 2 e LL mecc D suy ua Y 1 Vi gt Ww S We M KA gt t Zone Circulation Pump Red positive wire will not be disconnected for the purging procedure Alligator Clip to be connected to the Blue Wire s Spade Terminal Spade Terminal disconnected from the opposing wire Opposite end of the Alligator Cable to be connected to a ground source Page 109 2009 Aqua Hot 450
66. erify that either the jumper is in place that connects pins JP5 and JP8 together or if there is a power wire hooked up to the JP8 terminal verify that it is receiving 12 Volt D C from the Motor home s batteries iii If the JP8 pin does have 12 Volt D C but pin 3 on the JP4 terminal does not have power replace the electronic controller 12 Volt D C from coach house batteries Fuse for Webasto Blower Motor Page 55 SECTION 10 DIESEL BURNER COMPONENTS Diesel Burner Motor continued RPM Test 1 Disconnect the ignition cables from the ignition electrodes Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its wires from the C Plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor and clutch halves are exposed NOTE It may be necessary to remove the diesel burner to remove the bottom two screws securing the protection cap in place Follow the direction on detaching and reattaching the diesel burner in section Place a few wraps of black electrical tape around the clutch halves and then place a small piece of reflective tape over the black tape Disconnect the motor s black and brown wires from the C plug harnesses black and brown wires 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Connect the m
67. erify that the fluid level sensor s wires are securely installed in the terminal strip on the wire harness as well as tightly fastened to the electronic controller The fluid level sensor requires power to operate and possesses a third wire for power 17 which advances from the sensor to join the red 1 wire on the PUMP 3 terminal on the electronic controller s JP3 plug NOTE If pump number 3 shorts out i e indicator light is red it will cause the Low Tank Level Cutoff light to illumi nate red 4 Verify the functionality of the fluid level sensor by com pleting the following A Remove the faceplate from the electronic controller B Install a jumper wire on the JP3 plug between pins 15 and 16 between LWCO I and LWCO O on the electronic controller in order to bypass the flui level sensor If the Low Tank Level Cutoff indicator light on 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS the electronic controller extinguishes when the jumper wire is installed inspect the wire harness for damaged or severed wires If no wires are found to be damaged or severed follow the instructions in this section to replace the fluid level sensor If however the Low Tank Level Cutoff indicator light continues to illuminate once the jumper wire 1s installed follow the instructions in this manual to replace the electronic controller Rep
68. f the ignition electrodes with a course sponge 2 If the ignition electrode s electrical insulator is cracked or damaged the ignition electrode must be replaced The electrode adjustment gauge is used to set the gap between the ignition electrodes The electrode adjustment gauge is located on the outside surface of the diesel burner head on the left hand side Ignition Electrode Adjustment Procedure 1 Follow the directions for detaching reattaching the diesel burner in section Of this manual 2 Using a 10mm socket slightly loosen the retaining clamp bolt 3 Place the electrode adjustment gauge on the nozzle manifold hex and insert the metal tips of the ignition electrodes into the appropriate notches of the elec trode adjustment gauge D A y Retaining Ignition Clamp Cables Electrical Insulators Wf Igniton Z 3 Eu 4 Retaining metal tips o Electrode EE eme DN SECTION 10 DIESEL BURNER COMPONENTS NOTE Be sure not to over tighten the retaining clamp bolt when readjusting the ignition electrodes Over tightening the retaining clamp bolt will bend the retaining clamp and prevent the photo disc from floating freely Not allowing the photo disc to float freely will cause poor combustion and result in a smoky exhaust A bent retaining clamp can be re straightened with a punch and hammer Lay the clamp s beveled side down on a solid flat surface and align the
69. haust must be able to freely exit away from the vehicle without any obstructions Two inch standard automotive type exhaust piping should be used with a maximum of two 90 degree pipe bends and should not exceed 20 feet The 3 inch and 4 inch black pipe nipples and the ex haust elbow originally supplied with the Aqua Hot must be present mA ws Depth of Motorhome Bay Floor Mounting Tray Flange 4 inch Nipple 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Page 17 This section details various components of the Aqua Hot that may require troubleshooting and or replacement in the event of a malfunction The diesel burner and its components are detailed in Section 10 of this manual Replacement parts can be ordered through Aqua Hot s Web site at www aquahot com or by calling 1 800 685 4298 If additional assistance is needed the Technical Support Team can also be reached Monday through Friday from 7 00 AM to 4 00 PM Mountain Standard Time at 1 800 685 4298 Sensors Switches Interlock Switch The interlock switch is a safety device designed to ensure that the Aqua Hot s access cover is securely installed before allowing the diesel burner to operate Troubleshoot the interlock switch if the following condition has occurred e The diesel burner fails to operate e The diesel burner switch light does not illuminate Troubleshooting NOTE The inter
70. hen plug the B plug back into the diesel burner controller to activate the diesel burner After approx 20 seconds the fuel solenoid will click and a fine mist of fuel should appear from the fuel nozzle in a cone shaped spray pattern Figure 48 Page 62 SECTION 10 DIESEL BURNER COMPONENTS Fuel Nozzle 2 When replacing the fuel nozzle be sure to tighten 6 Remove the B plug from the diesel burner control the nozzle loosen it a 1 4 turn and then firmly re ler tighten This will establish a seated fit and avoid any leaks 7 Ifthe cone shaped spray pattern did not appear fol low the troubleshooting guides for the following An adjustment of the ignition electrodes may be components and verify they are operating properly necessary after replacing the fuel nozzle Follow the ignition electrode adjustment procedure found A Fuel Solenoid in the ignition electrode section of this manual B Fuel pump C D C High Limit thermostats 3 After replacing the fuel nozzle reattach the diesel 8 Ifthe components listed above are operating proper burner head ly and there 1s still no fuel coming out of the nozzle replace the fuel nozzle A DAN G E R A Fuel Nozzle Cleani d Mai Be sure to reattach the diesel burner head prior to Fuet Nozzle Cleaning and Maintenance switching the heater ON Failure to do so may result in ignition of the diesel burner and serious bodily injury The fuel nozzle is a precision
71. her plugged into shore power or that the generator is running to provide AC power 2 Verify that both the Electric Heating Element Status and the Heating Status indicator lights on the electron ic controller are illuminated If the Electric Heating Element Status indicator light on the electronic controller is not illuminated complete the following A Verify that the electric element switch on the interi or switch panel is on B Install a jumper wire on the JP2 plug between pins 52 and 53 ELECT O and ELECT I on the electronic controller to bypass the electric element switch If the Electric Heating Element Status indicator light illuminates on the electronic controller with the jumper wire installed check the Electric Ele ment Switch on the interior switch panel for func tionality If the Electric Heating Element Status indicator light does not illuminate on the electronic controller 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS with the jumper wire installed follow the instruc tions in this manual to replace the electronic con troller If the Heating Status indicator light on the electronic controller is not illuminated complete the following A Check the temperature of the Aqua Hot s boiler tank If the boiler tank temperature is below 158 F trou bleshoot the control thermostat If the boiler tank is abov
72. hick flat washer and steel drive gear on the threaded end of the combus tion air blower s shaft Thread the new retaining nut on the combustion air blower s shaft until it is finger tight DO NOT TIGHTEN Dished Surface Washer Dished Surface Washer Flat Washer Page 69 12 13 14 SECTION 10 DIESEL BURNER COMPONENTS Place a feeler gauge between the combustion air blower and the flat surface of the blower casing Slowly tighten or loosen the retaining nut holding the combustion air blower until a 003 005 gap is achieved Remove feeler gauge Spin the combustion air blower to ensure a friction free rotation If the combustion air blower is rubbing loosen the retaining nut slightly and lightly tap on the combus tion air blower s shaft opposite side then readjust the gap Reattach the blower housing to the blower casing using the four blower housing screws Reinstall the clutch half on both the motor s shaft and the com bustion air blower s shaft Attach the motor and flange assembly with the recessed edge of the mo tor flange in line with the wiring access slot of the blower casing to the blower housing with the three hex head screws Reconnect the black and brown wires of the motor to the C plug harness black and brown wires Feed the C plug harness yellow and brown wires back through the wiring access hole in the protection cap Blower Housing Combu
73. hot water interior heat and engine pre heat Diesel Burner LD Plate 520000154 Assembled in USA V Heater Model DBW201 0 75 Voltage Power 1 2V 60W Output 13 2kW 45000Btu h Fue Type Diesel No 1 No 2 and Artic rating Pressure 2 bar 29PSI TRE LUE NM M Heater No 90915E Vers 75 Serial No 12 Year of installation 08 09 10 2 Webasto Diesel Burner Diesel Fuel Supply Banjo Air Intake Page 42 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Vener MESS D D sp Diesel Burner Controller Motor Ignition Coil Clutch Combustion Air Blower Fuel Solenoid Valve Electrode Boots Ignition Electrodes Fuel Nozzle 16 10 11 12 13 14 15 16 15 14 13 SECTION 8 DIESEL BURNER Heat Exchanger Combustion Chamber Exhaust Port Flame Sensor Fuel Pump Fuel Tubes Supply Return Combustion Air Intake Port with Adjustable Shutter 8 9 12 11 10 Page 43 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Operation sequence once the Aq ua Hot s Diesel switch is turned ON NOTE The Diesel switch s indicator light will illuminate anytime the Diesel Burner switch is in the ON position The Motor 2 which turns the Combustion Air Blower 5 and drives the Fuel Pump 14 will begin to operate NOTE If the Aqua Hot s coolant temper ature is approximately 190 F
74. ick If after the initial release of the stuck check valve it contin ues to stick follow the instructions in this section to replace the check valve Page 25 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve 3 Using constant tension pliers loosen and slide back the constant tension clamp securing the hose to the defective check valve 4 Remove the hose from the defective check valve Zone Check Valve 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS 10 11 Unscrew the defective check valve from the Aqua Hot s boiler tank Remove the hose barb and the 1 2 inch coupler from the defective check valve Clean the hose barb and coupler then wrap the hose barb and the 1 2 inch coupler pipe threads with Teflon tape Install the hose barb and 1 2 inch coupler on the re
75. ide B of the blower casing Push all the contents of the bearing kit out of the blower casing s bore bearing cavity Discard the retaining nut steel drive gear snap rings bear ings spacer tube and washers as replacements are provided in the new bearing kit 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A 10 11 12 Be sure to inspect the blower casing s bore bearing cavity for signs of damage due to potentially seized bearings If damage is present the blower casing must be replaced Install a new snap ring into side A of the blower casing Once the snap ring is in place insert the remaining contents of the new bearing kit into side B of the blower casing starting with the wave washer Secure the bearing kit assembly in place with the remaining snap ring Inspect the combustion air blower for warping and or damage If warping or damage is visible the combustion air blower must be replaced Reference Figure for exact placement of the three washers that slide over the threaded end of the com bustion air blower s shaft prior to installation Fail ure to follow the correct order and direction of the dished surfaces on the washers will result in a re stricted rotation of the combustion air blower Slide the combustion air blower s shaft with the three washers up through the bearing kit assembly until the threaded portion appears on side A of the blower casing Place the new t
76. il the retaining clamp returns to proper form 4 Remove the electrode adjustment gauge Page 102 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 11 Inspect Photo Disc Photo Disc If the photo disc is not free floating the electrode clamp bolt has been over tightened and has bent the electrode clamp Using a l 10mm socket remove the electrode clamp and re straighten Lay the clamp s beveled side down on a solid flat surface and align the thick end of the punch at dead center Tap the punch lightly until the retaining clamp returns to proper form Step 12 Re Install Diesel Burner NOTE When reinstalling the diesel burner be careful not to damage the photo disc or bend the electrodes Also be careful to not pinch any wires between the burner and the Aqua Hot Tank 1 Align the Diesel Burner with the Aqua Hot using the alignment tabs welded on the Aqua Hot 2 Swing the Eye Bolts around the Ears on the diesel burner and securely tighten using a 10mm socket with a 10 inch long extension Use extreme caution when tightening down the eye bolt nuts over tightening of the eye bolt nuts can cause the aluminum blower casing to crack Torque Specifications Approximately 20 40 in Ibs Page 103 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX E AQUA HOT MAINTENANCE Step 13 Re
77. ion coil wires Remove the four ignition coil screws that secure the ignition coil in place Disconnect the ignition coil s black and brown wires from the C plug harness yellow and brown wires Ignition Coil Ignition Cable Brown Wire to Diesel Burner Yellow Wire to Diesel Burner Page 71 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SECTION 10 DIESEL BURNER COMPONENTS Ignition Coil 2 Connect the new ignition coil s black and brown wires to the C plug harness yellow and brown wires Attach the ignition coil to the pro tection cap with the four ignition coil screws then reconnect the ignition cables to the ignition elec trodes NOTE In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review the section for detaching and reattaching the diesel burner Replacement Procedure NOTE If the new ignition coil does not function check wire connections and ensure they are properly connected 1 Disconnect the ignition cables from the ignition electrodes Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil and disconnect its wires from 3 Follow the instructions for reattaching the diesel the C plug harness wires prior to removing burner and test for proper operation Figure 57
78. is reached Page 7 SECTION 2 AQUA HoT 450 DE OVERVIEW Aqua Hot 450 DE Technical Specifications Diesel Burner EN 56 000 BTU hr Diese Burner Fuel ConsunIDHOR C OBOIDUIOUS C DOEQEDORD a EE 0 40 gal hr Heater Voltage Maxam Ee 12 Volt DC 60 watts Electric Lieauno Element SpeettcAHOB s ons asse the Bets inea trot eite nto Drive Rr eV eine Rete Rea mela 120 Volt AC 1650 watts Zone Heat Ci Sula Oi Pump SC CUA AT OIIS ecce ir hin NN em aro MIT uti on stad ens 2 12 Volt DC 21 watts each Kette E ZONE RN maximum of 5 plus Engine Preheat Domestic Water Heating CAR i ia eae aaisan aa aisiais ouiin isea continuous on demand E bhi CAS E Generally Recognized as Safe by the FDA Propylene Glycol D E E E E T E A E E 12 H x 18 5 W x 30 L boe Eege approximately 127 lbs KA approximately 184 lbs NOTE All vehicle installations must comply with the requirements listed in the Recreational Vehicle Industry Association s RVIA ANSI NFPA 1192 Handbook for Recreational Vehicle Standards To receive a copy of this handbook and other perti nent RVIA Standards write to Recreation Vehicle Industry Association 1896 Preston White Drive P O Box 2999 Reston VA 22090 0999 call them at 703 620 6003 or visit them online at www tvia org Page 8 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A AQUA HOT 450 DE OVERVIEW SECTION 2 ure 2 Fi 20EF enb
79. k up wrench to tighten 10 Install the pressure relief valve onto the replacement tempering valve 11 Reconnect the pex pipe and fittings to the tempering valve and Aqua Hot Be sure to inspect the rubber seals and replace if necessary 12 Reconnect the motor home s water lines to the temper ing valve assembly 13 Turn the motor home s water pump back on and check for leaks and the presence of hot domestic water 14 Verify that the replacement tempering valve has been set to the proper setting by taking a digital thermometer to a hot water faucet and set the water temperature between 115 F 123 F Page 27 SECTION 5 AQUA HOT COMPONENTS Figure 16 EH Valve Knob Pressure Relief Valve Tempering Valve Pumps 2 Turn on the interior room thermostat corresponding to the circulation pump not operating heating zones 1 and 5 operate with circulation pump 1 and heating zones s d S i Circulation Pumps 1 and 2 2 3 and 4 operate with circulation pump 2 Check the corresponding Heating Zone Status indicator lights on The circulation pumps first draw the heated antifreeze and E Be cceli scd c water heating solution from the Aqua Hot s boiler tank then propel it through the Hydronic heating system s interior heat if the Heating Zone States indicator light does noi plumbing illuminate complete the following Troubleshoot the circulation pumps if the following condi A Testall
80. l Solenoid Component Test NOTE If the fuel solenoid is not working troubleshoot the diesel burner s hi limit thermostats If they are tripped they will not allow the fuel solenoid to operate Locate and detach the C plug harness violet and Brown wires from the fuel solenoid 2 Connect the lead of a 12 volt DC power supply to the fuel solenoid s electrical terminal 3 Intermittently apply the lead of the power sup ply to the fuel solenoid s electrical terminal 4 Listen for the fuel solenoid to click i e open and close 5 If the fuel solenoid does not click it must be re placed Fuel Solenoid Replacement Procedure 1 Disconnect the C plug harness violet and brown wires from the fuel solenoid 2 Using an 8mm wrench remove the lock nut and flat washer from the end of the fuel solenoid shaft and then pull the fuel solenoid away from the nozzle 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A stand approximately 1 2 Remove the fuel sole noid shaft from the nozzle manifold using a 16mm wrench Discard the shaft and valve kit as replace ments are provided with the new fuel solenoid as sembly 3 Insert the contents of the new fuel solenoid valve kit into the new fuel solenoid shaft Slide the new fuel solenoid onto the fuel solenoid shaft Thread the new fuel solenoid shaft with fuel solenoid to the fuel nozzle manifold and tighten S
81. lacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve 3 Disconnect the fluid level sensor s wires by releasing the clip securing the plug to the sensor and pulling the plug away from the sensor 4 Using a 7 8 wrench unscrew the fluid level sensor from the Aqua Hot s boiler tank It may be necessary to use a 7 8 Crow s Foot wrench 5 Add a liquid thread sealant such as Loctite to the threads of the replacement fluid level sensor 6 Screw the replacement fluid level sensor into the port on the Aqua Hot s boiler tank and tighten with a wrench 7 Plug the fluid level sensor s wires into the replacement sensor and secure with the clip 8 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution Page 19 Fluid Level Sensor Thermostats Control Thermostat The control thermostat is installed into the Aqua Hot s boiler tank and monitors the temperature of the antifreeze and wa
82. led into the zone outlet ports for each heating loop to ensure that the antifreeze and water heating solution only flows in one direction If the heating solution attempts to backflow into the boiler tank the check valve closes to prevent that from happening Troubleshoot the check valves if the following condition has occurred e There is a lack of interior heat in a particular zone Troubleshooting 1 Verify that the heating zone is operating properly by checking the following A Check the electronic controller to insure that both the Heating Zone Status and corresponding pump status Pump 1 or Pump 2 indicator lights are illuminated green SECTION 5 AQUA HoT COMPONENTS Low Temperature Cut Off Thermostat B Check the circulation pump for operation by visual ly inspecting it for rotation of the pump 2 With the circulation pump operating tap on the check valve and wait five minutes to evaluate if interior heat 1s now present If interior heat is present after tapping the check valve the check valve was stuck closed and no further action 1s necessary 3 Check the Aqua Hot s antifreeze and water heating solu tion s ratio of water to propylene glycol The mixture ratio should be approximately 50 50 If the solution is comprised fully of antifreeze 100 the check valves will continue to stick NOTE Storing the motor home for an extended period of time can cause the check valves to st
83. ler tank to the morot home s warm engine and back to the boiler tank Through this process the boiler tank is kept heated which reduces the time required to bring the tank to operating temperature for interior heat and continuous do mestic hot water This motoraide feature is part of the en gine preheating feature and plumbing system and requires no action on the user s behalf to function Interior Heating System The interior heating system is responsible for providing heat to the motorhome s interior in order to maintain the tempera ture at a comfortable level For interior heating it is the room thermostats that trigger the Aqua Hot s interior heating system When a thermostat rec ognizes that heat is required in a particular area it sends a signal to the Aqua Hot s electronic controller calling for heat The Aqua Hot responds by activating the circulation pump for that zone which sends the heated antifreeze and water heating solution through the Heating Loop correspond ing to the zone requesting heat The fans on the heat ex changers in the zone calling for heat are also activated there fore as the heated solution flows over the heat exchanger s fins the heat is transferred to those fins and dispersed into the interior of the motor home by the fans Until the thermo stat signals that heat is no longer required the Aqua Hot will continue to send the heated antifreeze and water solution through the loop which retur
84. lock switch will prevent the diesel burner from operating without the access cover intact therefore the switch will need to be manually pressed during testing for the switch s functionality 1 Turn the diesel burner switch on from the interior switch panel and ensure that the boiler tank has sufficiently cooled in order to require heat from the diesel burner 2 Verify that the Heating Status and Diesel Burner Status indicator lights are illuminated on the electronic controller 3 Disconnect the two yellow wires from the interlock switch noting that wire 24 is connected to the terminal labeled NO and wire 25 is connected to the terminal labeled COM 4 Using an ohmmeter check the interlock switch for con tinuity while the button is pushed in 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS If continuity is not present with the button pushed in follow the instructions in this section to replace the in terlock switch Replacement Procedure A DANGER FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Disconnect the interlock switch s wires by pulling the quick connectors from the switch s spade terminals 2 Release the interlock switch from the Aqua Hot cabinet by pushing in on the locking tabs and pulling the inter lock switch
85. met and slide into the appropriate notch on the blower casing Reconnect the ignition cables to the ignition elec trodes Reinstall the photo disc and secure it in place with the retaining clip Reconnect the flame sensor s green wire to the green C plug harness and the blue wire to the C plug harness violet wire Install rubber grommet around the harness wires and set into place Check the ignition electrodes for proper adjustment prior to reattaching the diesel burner Follow the directions for reattaching the diesel burner in section 9 of this manual Page 66 Fuel Pump continued SECTION 10 DIESEL BURNER COMPONENTS Grommet Blower Casting Left Grommet Blower Casting Right Sensor Flame Clip Retaining Photo Disc Disc Photo Pump Fuel Tube Fuel High Pressure Bolt Banjo Gasket Ring Copper Tube Fuel Banjo Supply 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Return Tube Fuel Banjo Return Screw Mounting Fuel Pump Washer Lock Fuel Pump Nozzle Fuel 0 35 GPH Manifold Fuel Nozzle Brass Screw Manifold Plate Plate Manifold Gear Fuel Pump Nylon Ring Snap Page 67 SECTION 10 DIESEL BURNER COMPONENTS Bearings The bearings support the combustion air blower s shaft and allows the blower to turn smoothly In order to perform the following procedures it is necessary to detach and reattach the diesel burner h
86. mine the number of heat exchangers installed with the Aqua Hot Heating System NOTE Each heating zone FAN circuit can supply up to 2 0 amps of direct current 3 Consult the heat exchanger s manufacturer for amp draw information NOTE Each Aqua Hot Cozy heat exchanger draws 23 amps of direct current Each Aqua Hot Whisper heat exchanger draws 38 amps of direct current 4 Determine the total amperage draw for all heat exchangers installed For example if six Aqua Hot Cozy heat exchangers have been installed multiply the amperage draw of each heat exchanger 23 amps by the number of heat exchangers 6 The total amperage draw in this scenario would be 1 38 amps 5 Add the total heat exchanger amperage draw to the amperage of the installed Aqua Hot Page 82 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX B WIRE GAUGE INFORMATION For example an Aqua Hot 600 D with six Aqua Hot Cozy heat exchangers has a total amperage draw of 23 38 amps Determining the Proper Wire Gauge 1 Measure the total length of the wire required for the distance between the vehicle s battery and the elec tronic controller for Aqua Hot models 450 DE 450 DM 525 D 600 D and 675 D and the heater itself for the Aqua Hot 375 D model 2 Using the determined length and total amperage draw consult the wire gauge chart included in this bulle tin Round up to the closest amp draw listed on the left the
87. mo ee M yanyna 1N3N373 1v3H 3Hd 3S3id DIM19313 NING TANVd HOLIMS de S WE 3NOZ ONILV3H wooudag ES cS e e is XVW SLYM EZ 06 OGAZL SN3ONVHOX3 LVIH i A202 OL S e KecH 3NOZ ONILV3H Z WOON HIv8 t DEE 06 s VI SUN E ee S33ONVHOX3 1V3H A202 OL IvISOWISIHI 3NOZ ONILW3H XNYL HILVM HS3a4 XYW SLYM Z OQAZL SSIONVHOXI 1v3H AZOD Ol Aie ONILVIH WWNOUdO 3NOZ ONILV3H IvVISOWX3HL N3HOIP WOO3 ONIAN XVW SLYM PZ OQAZL S33ONYHOX3 1YJH i A202 OL Page 81 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX B WIRE GAUGE INFORMATION Because all Aqua Hot heating systems are designed to operate only when there is an adequate supply of DC Direct Current voltage it is imperative that the proper wire gauge be determined and used for the DC power supply and ground wires This bulletin address es how to determine the DC amperage draw of the heating system including heat exchangers then how to determine the proper wire gauge based upon those findings for a specific application Aqua Hot Base DC Model Amp Draw Aqua Hot 375 D 26 Amps Aqua Hot 450 DM 19 Amps Aqua Hot 450 DE 19 Amps Aqua Hot 525 D 26 Amps Aqua Hot 600 D Aqua Hot 675 D excludes heat exchangers Determining the DC Amperage Draw of the Heating System 1 Review the chart below for the amperage draw of each Aqua Hot heater excludes heat exchangers 2 Deter
88. mostatically or manually the Fuel Solenoid Valve 6 closes which interrupts the supply of die sel fuel to the Fuel Nozzle 9 The Motor 2 will continue to run for approximately three 3 addi tional minutes This process is re ferred to as the Purge Cycle which cools the heater s internal compo nents and purges the Combustion Chamber 11 of any residual exhaust gases NOTE When the Aqua Hot s Diesel Burn er is switched OFF by the VDC VAC Control Thermostat the following process will take place 1 The Motor 2 will shut off once the three 3 minute Purge Cycle has expired THEN 2 The Aqua Hot s Diesel Burner will automatically turn back ON once the coolant reaches the preset temperature of approximately 160 5 F Summary The Aqua Hot s Diesel Burner is operational anytime the operator moves the Diesel Burner Switch to the ON position The Diesel Burner will then automatically maintain the coolant temperature in the Aqua Hot s Boiler Tank with out additional involvement from the operator Page 44 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 8 DIESEL BURNER Diesel Burner Operations The following sequence illustrates how the Diesel Burner as a diagnostic tool to determine at what point in the diesel operates once it 1s activated Also if diesel burner malfunc burner s operation the malfunction is occurring Use the tions ar
89. mp 6 Release the pump from the mounting bracket by pulling on each Nylatch Plunger then remove the defective pump from the Aqua Hot 7 Slide the hoses back onto the replacement pump and set the constant tension clamps back into place Page 31 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS 8 Install the replacement stir pump onto the mounting bracket by aligning the Nylatch Plungers to their respec tive holes and pushing the plungers in to secure the pump to the bracket 9 Reconnect the wires on the replacement pump to the wires connected to the heater by uniting the red quick disconnect terminals 10 Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution DANGEF trront c tA Page 32 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Electrical AC Electric Heating Element The electric heating element uses AC power as an alternate power source for heating the Aqua Hot s boiler tank Troubleshoot the electric heating element if the following condition has occurred e There is a lack of hot domestic water and interior heat when the electric element is selected as the heating source Troubleshooting NOTE For continuous domestic hot water to be present the diesel burner must be selected also as a heating source 1 Verify that the motor home is eit
90. mponents prem aturely Therefore concentrated propylene glycol should be diluted with distilled de ionized or soft water that is 80 PPM or less in total hardness The local water agency should have up to date water quality reports that should indicate if the local tap water is within this guideline Antifreeze Terms and Mixture Ratio The following information addresses the process of selecting an antifreeze and water mixture ratio that provides adequate freeze boiling and rust anti corrosive protection A 50 50 mixture of propylene glycol water ratio is recommended which will result in a freeze point of approximately 28 F and a boil point of approximately 222 F The following information should be utilized for the purpose of clarifying some terms commonly associated with anti freeze Page 13 Freeze Point and Burst Point Antifreeze lowers the freezing point of any liquid to which it has been added by preventing the formation of ice crystals however as the ambient temperature continues to decline the water in the solution will attempt to attain a solid state The point in which the water begins to solidify is termed the Freeze Point Although the water in the solution has be gun to freeze producing a slushy consistency the anti freeze in the solution will continue to combat the normal expansion of the solution as it freezes The point in which the solution can begin to expand due to colder tempera
91. n round up to the closest length at the top of the chart For example an Aqua Hot 600 D heater with six Aqua Hot Cozy heat exchangers with the electronic con troller placed 15 feet from the vehicle s battery would require an 8 gauge wire Wire Gauge Chart AMERICAN BOAT AND YACHT COUNCIL RECOMMENDATIONS T TOTAL CONDUCTORS SIZES FOR 3 DROP IN VOLTAGE CURRENT Length of Conductor from Source of Current to Device and back to Source Feet OW CIRCUIT IN AMPS 10 15 2 25 30 40 50 60 70 60 390 3100 110 120 130 140 150 160 170 12 Volts 3 Drop Wire Sizes gage Based on Minimum CM Area Page 83 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure A fuel pressure gauge is used to properly check the fuel pump s pressure setting The fuel pump is preset to 145 PSI Perform the following procedures to check for a proper fuel pressure setting NOTE In order to perform the following procedure it is necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching instructions Step 1 Remove the diesel burner Figure C1 1 Refer to the section on detaching reattaching the diesel burner to detach the diesel burner Step 2 Install fuel line bypass fittings onto the diesel burner Figure C2 1 4 Fuel Tube unions d 1 Locate the 1 4 fuel tube unions
92. n system Page 77 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 11 TROUBLESHOOTING IF THERE Is A LACK OF DOMESTIC HOT WATER 1 General information l 2 The heater 1s only rated for water flow of 1 5 GPM The heater 1s only rated for a 55 F temperature Rise on the cold water coming into the unit The diesel burner must be on for continuous hot water the electric element is for lim ited use only 2 Things to test for a lack of hot water problem ke 2 Aqua Hot Heater Bypassed Outside Water Faucet is left on Washing Machine Valve has gone bad Antifreeze Concentration 1s incorrect a 30 50 antifreeze concentration Operating Range of the heater I E Control Thermostat 1s incorrect a 155 F 185 F Water Flow is too fast a Must be 1 5 GPM or Less Mixer Valve is stuck knob does not turn freely Low Temperature Cut off Thermostat 1s not functioning properly a Needs to trip within 1 2 Minutes when running hot water b Needs to turn the stir pump on if the diesel burner switch is on as well Stir Pump is not functioning properly a Needs to be running when the diesel burner switch is on and the Low Temperature Cut Off thermostat is Tripped b Hold onto both upper and lower hose to make sure both get hot Page 78 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 11 TROUBLESHOOTING
93. n then be tightened by using a 10mm socket wrench with a 10 inch long exten sion Use extreme caution when tightening down the eye bolt nuts over tightening of the eye bolt nuts can cause the aluminum blower casing to crack Torque Specifications Approximately 20 40 in Ibs Page 51 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 2 Reattach the fuel lines to the Aqua Hot Figure 38a Figure 38b M 1 Align the fuel lines on the diesel burner with the fittings on the Aqua Hot and using a 7 16 inch wrench tighten down both the supply and return fuel fittings CAUTION Be sure to remove the clamps off of the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to start ing the diesel burner or serious damage will occur to the diesel burner s fuel pump Step 3 Plug in the diesel burner s controller and mount 3 Locate the Diesel Burner s Controller and connect both plugs di E t TA rue pot var Ill nene de ep siren NOTE The Diesel Burner s Controller might have to be mounted onto the side of the diesel burner before the plugs are inserted into the control unit otherwise it might not be possible to mount the control unit Page 52 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 4 Rei
94. ng heat A cold boiler tank can ex pect to be brought to operating temperature by the diesel burner in approximately 10 to 20 minutes In order to obtain continuous hot water the diesel burner switch must be acti vated NOTE If the diesel burner fails to ignite the diesel burner status light will go out indicating to the customer the burn er has gone into a default To reset the default the diesel burner switch must be turned off for 5 seconds and then turned back on Additionally the diesel burner switch can be used to reset a low voltage condition This is accomplished by turning off the diesel burner switch for 30 seconds then turning it back on SECTION 3 INTERIOR SWITCH PANEL Electric Element Switch When the motor home is plugged into an AC power source e g shore power generator etc and the electric element switch is on the electric heating element will be used to pro vide heat to the boiler tank 1f the need arises A cold boiler tank can expect to be brought to operating temperature by the electric heating element in approximately 1 to 2 hours The electric element alone will not be able to provide continu ous hot water Engine Preheat Switch The engine preheat switch activates the engine preheat pump which draws the motor home s engine coolant through the boiler tank to heat it before returning it to the engine block to transfer the heat there Either the diesel burner switch or the electric el
95. ng the Diesel Burner WARNING Be sure to move the Diesel Burner switch on the Interior Switch Panel to the OFF position and disconnect the Diesel Burner s power supply before detaching the Diesel Burner from the Aqua Hot Failure to turn off the Diesel Burner and disconnect power could result in serious bodily injury CAUTION Be sure to clamp off the Fuel Supply and Return lines at the ports on top of the Aqua Hot prior to beginning this replacement procedure Step 1 Turn Off the Diesel Switch Electric Engine Preheat 1 Move the Interior Switch Panel s Diesel Burner switch to the OFF position Step 2 Remove the Access Cover d E Access Cover 1 Remove the Aqua Hot s access cover by locating 2 Unscrew the bolt securing the front of the cover in the bolts securing it in place place Page 48 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Step 3 Disconnect the Diesel Burner s Controller Locking Post 1 Controller Mounting Bracket 1 Locate the Diesel Burner s Controller and disconnect both plugs Step 4 Remove the fuel lines from the Aqua Hot 1 Locate where the fuel lines on the diesel burner 2 Using an 7 16 wrench loosen the nuts securing connect to the Aqua Hot Bulkhead fittings each fuel line to the Aqua Hot Page 49 2009 Aqua Hot
96. ns the cooled solution to the 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 1 INTRODUCTION TO THE 450 DE Aqua Hot s boiler tank to be re heated before being sent back through the loop again This process continues until the pre set temperature of the interior is reached and the interior room thermostat signals the electronic controller that heat is no longer required AC Circuit Although the diesel burner is the primary heating source for the Aqua Hot and is necessary for providing continuous do mestic hot water an alternate heat source exists for moderate temperatures which functions with an AC circuit Whenever the motor home is connected to an AC power source plugged into shore power or using a generator the Aqua Hot s electric heating element has the ability to function in order to provide heat for the boiler tank When the antifreeze and water heating solution falls below Operating temperature as determined by the control thermo stat a signal is sent to the electronic controller requesting heat Because the electric element switch is activated on the interior switch panel the DC power from the electronic con troller is permitted to flow to the AC relay which activates the relay in order to allow AC power to flow to the electric heating element When the electric heating element receives power it becomes active and supplies heat to the boiler tank until operating temperature
97. nstall the Access Cover NOTE The access cover must be installed prior to operation as a safety switch exists which will prevent the Aqua Hot from operating whenever the access cover is not properly installed Figure 40b Figure 40a Aqua Hot 450 D _ Cover Fastener 1 Reinstall the Aqua Hot s access cover 2 Securely tighten the three bolts securing the ac cess cover in place Page 53 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A S SS vu IN OP P Diesel Burner Controller Motor Ignition Coil Clutch Combustion Air Blower Fuel Solenoid Valve Electrode Boots Ignition Electrodes Fuel Nozzle 16 SECTION 10 DIESEL BURNER COMPONENTS 10 11 12 13 14 15 16 15 14 13 Heat Exchanger L Figure 41 Combustion Chamber Exhaust Port Flame Sensor Fuel Pump Fuel Tubes Supply Return Combustion Air Intake Port with Adjustable Shutter 8 9 12 11 10 Page 54 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 10 DIESEL BURNER COMPONENTS Diesel Burner Motor If there is no 12 Volts D C present on the C 2 pin con The motor drives the combustion air blower and the tinue NOTE fuel pump In order to perform the following proce dures it may be necessary to detach the diesel burner head The Aqua hot 600 Series is equipped with a 20A Fast Blow Fuse located on the red 20 wire between
98. ntinuity follow the instructions in this section for replacing the control thermostat If continuity exists complete the following a Inspect the control thermostat s wiring and connections b Install a jumper wire on the JP3 plug between pins 13 and 14 TSTAT I and TSTAT O on the electronic controller in order to bypass the control thermostat NOTE The diesel burner and or electric element switch must be in the on position also for the Heating Status indicator light on the electronic controller to illuminate If the Heating Status indicator light on the electronic controller does not illuminate with the jumper wire installed follow the instruc tions in this manual to replace the electronic controller Page 20 Control Thermostat Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled 2 Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve 3 Disconnect the defective control thermostat s wires by separating the quick disconnect terminals 4
99. on Coil Ignition Electrodes Combustion The combustion s flame is detected by the Flame Sensor and the gnition Coil is then automatically switched off no more spark across the gnition Electrodes Flame Hot Exhaust Sensor Gases Page 46 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 8 DIESEL BURNER L Diesel Fuel Spray Figure 31 mae Combustion Air rss The particular component begins to operate CT The component is currently operating Diesel Burner Operation continued The Diesel Burner will continue to produce heat in this manner until it is switched off either manually or by the VDC VAC Control Thermostat which occurs when the coolant temperature in the Aqua Hot s Boiler Tank reaches 190 5 degrees Fahrenheit Once the Diese Burner has switched OFF the Motor and Combustion Air Blower will continue to operate for approximately 2 3 minutes This process is referred to as the purge cycle Cool Exhaust Gases NOTE Whenever the Diesel Burner is switched off by the VDC VAC Control Thermostat it will automatically be reactivated once the Aqua Hot Boiler Tank s coolant reaches the preset temperature of approximately 160 5 degrees Fahrenheit Page 47 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 9 DETACHING AND REATTACHING THE DIESEL BURNER Instructions for Detachi
100. on the bottom side of diesel burner Page 84 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 2 Install fuel line bypass fittings onto the diesel burner continued Figure C3 2 Using a 13mm and a 9 16 wrench remove Steel Fuel lines from the diesel Burner Figure C4 3 Using a 13mm and a 9 16 wrench install the fuel bypass fittings onto the diesel Burner Page 85 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3 Installing the fuel pressure gauge Figure C5 Figure C6 2 Using a 5 8 and a 3 4 wrench install the fuel pressure gauge Page 86 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX C FUEL PRESSURE CHECK AND ADJUSTMENT Instructions for Checking Fuel Pressure Step 3 Running the burner off of an external fuel source Figure C7 1 Using an external fuel source and rubber fuel line hook the Webasto burner supply and return fuel lines up to run off of the external fuel source WARNING A spark will appear across the ignition electrodes for a brief moment after the diesel burner has been activated DO NOT attempt to make any fuel pressure adjustments until the spark has disappeared Failur
101. or Circuit Test Locate the diesel burner controller s B plug and C plug Use a jumper wire to make a connection from the C 1 location to the C 7 location Turn the diesel switch ON and insert the probes of a DC voltmeter into the C 2 and C 5 locations If no voltage reading registers on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test Be sure to remove the jumper wire that was used to make the connection from the C 1 location to the C 7 location A fail ure to do so will result in an overheating condition during normal operation Ignition Coil Circuit Test Turn the diesel switch OFF and locate the diesel burner controller s C plug Also locate the VDC high limit thermostat and disconnect it s 2 way male plug from the white plastic 6 way female connector Insert the probes of a DC voltmeter into the C 8 and C 5 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmeter 18 25 seconds after the initial start up the diesel burner controller must be replaced Be sure to reconnect the VDC high limit thermo stat s 2 way male plug to the 6 way female plug The diesel burner will not ignite during normal operation if the VDC high limit thermostat is left disconnected Page 73 SECTION 10 DIESEL BURNER COMPONENTS Be sure to remove the jumper wire that was used to make the connection from the
102. or is not connected during this replacement procedure 3 Remove the AC access cover 4 Release the wires from the defective AC relay by re moving the corresponding screw terminals 5 Remove the defective relay by drilling the rivets that hold the defective relay in place 6 Rivet the replacement AC relay to the AC access cover 7 Using the wiring diagram in Appendix A connect the wires previously removed to the replacement AC relay 8 Reinstall the AC access cover Page 35 Electronic Controller Overview The electronic controller is an electronic circuit board that controls the electrical functions of the Aqua Hot heating system All wiring for the switch panel is connected to the electronic controller as well as the wiring circuitry from the Electric Heating 9 Element Status SECTION 6 ELECTRONIC CONTROLLER Aqua Hot unit Indicator lights on the front panel will illu minate red if there is a short circuit overload or fault condi tion within the system It also will indicate when circuits are functioning properly with a green indicator light Aqua Hot HYDRONIC HEATING SYSTEM rj Low Tank Level Cutoff Heating Status Engine Preheat Pump Low Battery Voltage Fault E Diesel Burner Status D Low Temp Cutoff Status Overioad Fault ELECTRONIC CONTROLLER Electronic Controller General Facts Nominal input voltage range 10 6V to 15V CUNT CIM SNR ET
103. otor s wires directly to a 12 volt DC power supply Turn the power supply ON and use a photo tachometer to test for a proper RPM reading At approximately 12 volts DC the RPM reading should be 4500 RPM s 300 RPM s If the motor s RPM reading is not within the above specs the motor must be replaced Test the diesel burner s bearings prior to reattach ing the diesel burner head or replacing the motor Worn bearings can cause lower than normal RPM readings and premature motor wear To properly test for worn bearings reference the bearings func tion test section Page 56 SECTION 10 DIESEL BURNER COMPONENTS Motor Replacement Procedure Be sure to move the Diesel Burner switch on the In terior Switch Panel to the OFF position and discon nect the Diesel Burner s power supply before de taching the Diesel Burner from the Aqua Hot Fail ure to turn off the Diesel Burner and disconnect power could result in serious bodily injury 1 Follow the directions for detaching the diesel burner in section 2 Remove the four ignition coil screws that secure the ignition coil to the protection cap Lift the ignition coil to disconnect its wires from the C plug harness wires prior to removing Remove the protection cap from the diesel burner so that the motor clutch halves are exposed 3 Remove the three hex head screws that secure the motor and flange assembly to the blower housing Remove the mo
104. own wires of the new motor to the C Plug harness yellow and brown wires Feed the C plug harness yellow and brown wires back through wiring access hole in the protection cap Reinstall the protection cap Reconnect the black and brown wires Reinstall the ignition coil and secure to the protec tion cap with the four ignition coil screws Follow the directions for reattaching the diesel burner in section Test for proper operation Page 57 SECTION 10 DIESEL BURNER COMPONENTS Motor Replacement Procedure continued Electrode Adjustment Gauge Figure 44 Blower Casting Motor Flange Protection Housing m H j ar 4 E i A Page 58 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Flame Sensor SECTION 10 DIESEL BURNER COMPONENTS 3 Connect the flame sensor s green and blue wires to The flame sensor is a photo resistive device which an ohmmeter supplies the diesel burner s controller with a DC voltage signal when it detects a flame When the 4 Check resistance by placing a shop rag over the flame sensor senses the light of the flame it will flame sensor s glass surface to simulate a no flame shut the ignition coil off and send a signal to the condition and then remove the rag and expose to a diesel burner controller indicating that everything is light source to simulate a flame condition wo
105. own and that all power sources have been disconnect ed Remove the faceplate from the electronic controller by removing the four screws securing it to the mounting bracket Disconnect the positive negative and secondary power if applicable wires from the electronic controller Disconnect the four terminal strips plugs from the elec tronic controller by loosening the screws on each strip plug and pulling each strip plug away from the electron ic controller Remove the electronic controller from the mounting Proper Pin Jumper Configuration Verify that the pin jumpers are configured as in the illus tration in this section If the pin jumpers do not match the illustration the Aqua Hot 450 will not function properly If the jumpers pins need to be reconfigured simply tug gently on the black cap covering the pins to pull the black cap off Reseat the cap on the pins appropriately as per the illus tration 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A an Aqua Hot 450 DE reference information in this sec tion for proper pin jumper configuration 8 Install each terminal strip plug back onto the electronic controller and tighten the screws on the terminal strips plugs to secure them to the board NOTE Check the terminal strips plugs for loose wires and tighten if loose 9 Connect the ground wire followed by the main 12 Volt DC power wire then the secondary power wire if ap
106. place ment check valve ensuring that they are installed properly with the hose barb on the arrow side of the check valve Install the replacement check valve onto the Aqua Hot s boiler tank The arrow on the check valve must point away from the boiler tank Slide the hose back onto the replacement pump and set the constant tension clamp back into place Refill the Aqua Hot s boiler tank with the antifreeze and water heating solution Page 26 Tempering Valve The tempering valve for the Aqua Hot mixes the heated do mestic water from the boiler tank with cold domestic water at a preset ratio to reduce the risk of scalding Troubleshoot the tempering valve if the following condition has occurred e There is a lack of hot domestic water Troubleshooting NOTE Prior to trouble shooting the tempering valve it is recommended to review the Lack of Hot Water Trouble Shooting guide in section 11 1 Inspect the tempering valve to ensure that it is not leaking 2 Test the temperature of the hot water using a digital thermometer at one of the hot water faucets Water Temperature should range between 115 F 123 F If the proper range cannot be set follow the instructions in this section to replace the tempering valve 3 Test the tempering valve s functionality by turning the knob If the tempering valve s knob does not turn freely fol low the instructions in this section to replace the temper
107. pli cable to the appropriate screw terminals on the replace ment electronic controller board Reference Appendix A for additional wiring information 10 Reinstall the faceplate onto the electronic controller and secure with the four screws previously removed Electronic Controller Board eo e 3 nis E D a e H j cal M D Le J e d on f d Th P a 14 e p Li Sr o co AT LG LL amp P c i dk em e H 2 d Te a TT em i t E at P i E Se d De Q D Bn uo SECTION 7 ELECTRONIC CONTROLLER INDICATOR LIGHTS Electric Heating Element Status This indicator light shows the status of the electric heating element by illuminating green for on red for fault or by turning off when the element switch is turned off If the light is off and the electric element switch on the interi or switch panel is off then the system is functioning correct ly If the indicator light is green and the electric element switch on the interior switch panel is on the system is also functioning correctly If the light is red and the electric element switch on the inte rior switch panel is on then there is a short in the electric element circuit This could be due to a bad connection a bad switch on the interior switch panel or an issue with the AC relay Heating Zone Status 1 5 These lights indicate the status of each motor home room thermosta
108. remove the flame sensor from the photo disc and clean with brake cleaner Page 59 SECTION 10 DIESEL BURNER COMPONENTS Flame Sensor Replacement Procedure 1 In order to perform the following procedures it is 3 Slide the tab of the new flame sensor into the pro necessary to detach diesel burner head Be sure to vided slot in the photo disc and secure in place with review the detaching attaching instructions in sec the screw Connect the flame sensor s green wire to tion the green C plug harness wire and the blue wire to the C plug harness violet wire 2 Remove the screw that fastens the flame sensor to the photo disc and detach the sensor s green and 4 Follow the directions for reattaching the diesel blue wires from the C plug harness green and vio burner in section 9 of this manual let wires and remove flame sensor Figure 46 Flame Sensor Green Green Wire to Diesel Burner NOTE his screw is used to fasten the Flame Sensor to the Photo Disc Remove when replacing the Flame Sensor Violet Wire to Diesel Burner Page 60 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Ignition Electrodes The diesel burner s ignition coil produces a high voltage ignition spark across the ignition electrodes which ignites the incoming air fuel mixture Cleaning and Maintenance 1 Polish away any carbon deposits that may have baked onto the metal tips o
109. rking properly If the flame sensor does not sense the flame it will shut the diesel burner down 5 If the flame sensor is operating properly the ohm in a default after 20 seconds meter should register high resistance over 100K Q when the glass surface is covered and less than 200 In order to perform the following procedures it is when exposed to a light source necessary to detach and reattach the diesel burner head Be sure to review the detaching attaching 6 Ifthese resistance numbers cannot be obtained ver instructions ify the flame sensor s glass surface is clean If the flame sensor is clean and the resistance numbers cannot be obtained the flame sensor must be re Component Test Ohms placed NOTE Be sure to calibrate your ohmmeter prior to check ing the flame sensor to proper resistance values Flame Sensor Maintenance In order to perform the following procedures it is 1 For light dirt dust and or carbon deposits simply necessary to detach the diesel burner Be sure to wipe off the flame sensor with a soft cloth review the detaching attaching instructions in sec tion 9 2 Should heavy carbon deposits be present complete Once the diesel burner has been removed Locate and detach the flame sensor s green and blue wires from the C plug harness wires d f v A 4 Flame Sensor Green Wire 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A ly
110. rmal Operation A Turn the Diesel Burner switch on and let the diesel burner run for a complete cycle until it shuts off on it s own B After the Diesel Burner has shut off turn on the interior heat run hot water until the Diesel Burner cycles back on When the diesel burner cycles back on check the exhaust for signs of smoke Page 105 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A APPENDIX F WINTERIZATION PROCCESS WARNING Not winterizing the Aqua Hot when freezing temperatures are present will result in serious damage to the Aqua Hot s Domestic Water Heating System Also be sure to use an FDA approved GRAS rated antifreeze for winterization NOTE The Aqua Hot can continue to be used for interior zone heating once the domestic water heating system has been drained and winterized The Aqua Hot s Domestic Water Heating System must be completely drained of domestic water and properly winterized any time the heater is stored where freezing temperatures may be experienced Winterizing the Domestic Water Heating System Please follow these instructions when winterizing the Aqua Hot s Domestic Water Heating System reference Figure F1 Completely drain the fresh water storage tank 2 Disconnect the domestic water demand pump s suction line from the fresh water storage tank 3 Attach an adequate piece of hose onto the suction side of the domestic water demand pump
111. rmostat Secure the AC access cover back into place Test for proper operation NOTE If the High Limit Thermostat is tripped it is recom mended to test the control thermostat for proper operation DC High Limit Thermostats The DC high limit thermostats serve as a safety measure in the event that the diesel burner continues to operate after the maximum operating temperature is reached The high limit thermostats allow the current for the diesel burner to pass through them until the boiler tank reaches a temperature of 215 F Should this temperature be reached the high limit thermostat blocks the current to the diesel burner s fuel sole noid valve which prevents the diesel burner from operating Troubleshoot the DC high limit thermostat if the following condition has occurred e The fuel solenoid on the diesel burner fails to operate Troubleshooting 1 Place a jumper wire between the blue and purple wires on the diesel burner s wire harness to bypass the high limit thermostats Check the Aqua Hot for normal oper ation NOTE Bypassing the high limit thermostats is for testing only and must not be used for the Aqua Hot s nor mal functioning 2 Disconnect the DC high limit thermostats wires then using an ohmmeter check each thermostat for continui ty If there is no continuity complete the following A Press the white reset button on the high limit ther mostat then re check for continui
112. rn the electric element switch on the interior switch panel on and check the electronic controller to ensure that the Electric Heating Element Status and the Heating Status indicator lights are illuminated 3 Using a voltmeter check pins 11 and 12 AC Relay and AC Relay on the JP3 plug for 12 Volts DC If 12 Volts of DC power are not present while the Electric Heating Element Status and Heating Status indicator lights on the electronic controller are illuminat ed follow the instructions in this manual to replace the electronic controller If 12 Volts of DC power are present complete the fol lowing A C Terminal Block AC Relay 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HoT COMPONENTS A Locate the AC wires connected to the AC relay pins 6 and 8 and remove the AC wires from the relay B Using an ohmmeter check the relay AC pins 6 and 8 for continuity If no continuity exists follow the instructions in this section to replace the AC relay Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIUOS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Also ensure that the motor home is not connected to shore power and that a generat
113. roller B Using a temperature sensor verify that the low temperature cutoff thermostat is above 90 F If the thermostat is below 90 F verify that the Aqua Hot is up to operating temperature and that a hot water faucet is not leaking 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS C Disconnect the low temperature cutoff thermostat s wires from the Aqua Hot s wiring harness then jump the wiring harness wires for the thermostat together to bypass the thermostat If the Low Temp Cutoff Status indicator light illuminates on the electronic controller with the thermostat bypassed follow the instructions in this section to replace the low temperature cutoff ther mostat 3 Ifthe Low Temp Cutoff Status indicator light does not extinguish when domestic hot water is being used or when the Aqua Hot falls below operating temperature complete the following A Using a temperature sensor verify that the low temperature cutoff thermostat is below 90 F which is necessary for the indicator light to extinguish B Inspect the wiring to ensure that the Aqua Hot is wired properly and that the low temperature cutoff thermostat has not been bypassed via jumper wires C Disconnect the low temperature cutoff thermostat s wires from the Aqua Hot s wiring harness 1 If the Low Temp Cutoff Status indicator light on the electronic controller extinguishes
114. s wires for continuity by completing the following a Disconnect the motor home from shore power shut off generator b Disconnect the wires from the electric heating element c Disconnect the wires from the AC terminal block d Check the black and white wires at the terminal block for continuity 4 Check the electric heating element for functionality by completing the following A Disconnect all power supplies B Remove the AC access cover C Remove all wires from the electric heating element D Using an ohmmeter check the electric heating ele ment for the proper ohms The Ohms reading should be between 8 5 9 5 ohms If the ohms reading is not between 8 5 9 5 ohms follow the instructions in this section to replace the electric heating element Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed Also because this replacement procedure will in volve the boiler tank and the potential for hot coolant be sure the heater has adequately cooled Drain the antifreeze and water heating solution from the Aqua Hot s boiler tank using the drain valve Remove the
115. sel Burner switch on the interior switch panel is in the off position the indicator light will not be illuminat ed If the indicator light turns red there is either a short in the wiring or the diesel burner is in need of servicing When checking the wiring be sure to verify that the diesel burner controller s harness connectors are completely locked togeth er Also verify the Photo Eye Wires have not been pinched Reference section 9 of this manual for additional diesel burner information Overload Fault This indicator light shows the status of the DC voltage ap plied to the electronic controller and the Aqua Hot Under normal operating conditions this indicator light is off This light illuminates red when the Aqua Hot is shut down due to excessive DC voltage over 14 8 Volts and or the electronic controller has overheated Once the excessive voltage issue is resolved the electronic controller will reset itself Page 41 Diesel Burner Overview The Aqua Hot s diesel burner is a device that ignites a mix ture of diesel fuel and air within a controlled setting to serve as a heat source The flame is established in a combustion chamber within the Aqua Hot s boiler tank and the heat Fuel Nozzle Diesel Fuel Return Banjo Max a SECTION 8 DIESEL BURNER from the flame is transferred to the antifreeze and water heat ing solution where it can be used for each system of the Aq ua Hot domestic
116. stem properly installed following the F igure D2 450D installation manual A Are there at least 5 heat exchangers installed in the RS Se EE Interior of the motor home Se B Are there cold air returns installed for every heat exchanger Reference Figure C Are the heat exchangers mounted as close to the hot air outlet grill as possible Reference Figure COLD AIR REGISTER HOT AIR OUTLET BASE BOARD TOE KICK AREA Return Air Return Air Return Ai 444 444 Ss Z T e 8 U EE a Indicates generally recommended Meter locations for the Cozy Figure D3 eat Exchangers D ry INFA Page 91 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Monthly Maintenance Check the antifreeze and water heating solution to ensure that it 1s at the proper level by visually checking the solution level in the expansion tank The level of the antifreeze and water heating solution within the expansion tank should only be checked when the Aqua Hot is at maximum operating temperature If additional antifreeze and water heating solution is re quired fill the expansion tank to the HOT level mark Be sure to reference Section 2 of this manual to ensure that the proper type of antifreeze is selected and mixed with high quality water at the correct mixture ratio Additionally it is recommended that the diesel burner be fired and allowe
117. sting inspect be filled with clean diesel fuel prior to installation exhaust for smoke Step 1 Test Run the Diesel Burner 1 Turn the Diesel Burner Switch to the on po Step 3 Run the Diesel Burner 4 Remove hose pinch off pliers sition 2 After the Diesel Burner has ignited inspect 1 Turn the Diesel Burner Switch to the on po the exhaust for smoke sition 3 Shut the Diesel Burner off and wait for unit 2 After the Diesel Burner has ignited let it to completely shut off burn for 1 2 minutes to purge the old fuel out of the nozzle holder to prevent contami NOTE The diesel burner can either be shut off by fth t 1 Turning the Diesel Burner switch to the off position RE 2 Disconnecting the control thermostat wires 3 Shut the Diesel Burner off and wait for unit 3 Unplugging the diesel burner controller to completely shut off Reference Figure E3 NOTE The diesel burner can either be shut off by 1 Turning the Diesel Burner switch to the off position Step 2 Replace the Fuel Filter 2 Disconnecting the control thermostat wires 3 Unplugging the diesel burner controller Reference Figure E3 1 Locate Fuel Filter 2 Using hose pinch off pliers clamp off both fuel lines going to the fuel filter Reference figure E2 Thermostat Connector Medii gere N WA 10 Micron Fuel Filter Diesel Burner Controller Plugs 2009 Aqua Hot 450 D Hydronic Heating System Service M
118. stion Air Blower w shaft Blower Housing Screws Dished Surface Washer Dished Surface Washer Flat Washer Snap Ring Bearing Spacer Tube Bearing Kit NOTE 15 16 ET 18 Side B Blower Casin O Ring Wave Washer Bearing Blower Casting Inspect the clutch halves for cracks and also ensure that the flat portion in each shaft hole is free of wear and tear Too much play on the shaft produc es a loud clacking noise If any cracks or wear are detected the clutch half must be replaced Reinstall the protection cap Reconnect the black and brown wires of the ignition coil to the C plug harness yellow and brown wires Rein stall the ignition coil and secure to the protection cap with the four ignition coil screws Reconnect the ignition cables to the ignition electrodes Fit the nozzle stand plate inside the cast aluminum blower casing and secure in place with the four noz zle stand plate screws Reattach the fuel supply and return lines to the diesel burner head Reconnect the blue and brown wires to the fuel solenoid s and electrical terminals Al so reconnect the flame sensor s green wire to the green C plug harness wire and the blue wire to the C plug harness violet wire Follow the instructions for reattaching the diesel burner in the detaching reattaching section in this manual Side A R
119. t and the respective heat exchanger fan s The indicator light will illuminate green when the system is on and functioning properly red when on and not functioning and the light will be off when the system is off If a fault condition occurs this could be due to a wiring is sue a faulty thermostat or issues with the heat exchanger fans Low Battery Voltage Fault This indicator light illuminates red when the DC voltage is below 10 5 Volts for Longer than 5 minutes and it will be off when the system has adequate voltage If the light becomes red the switch may be reset after re storing voltage by pressing the Low Voltage Reset Button on the electronic controller with a long thin nonmetallic object or by turning the diesel burner switch on the interior switch panel off for 30 seconds then turning it back on Low Temp Cutoff Status The Low Temp Cutoff thermostat shuts the interior heat off when domestic hot water is being used and activates the stir pump in conjunction with the diesel burner switch When the indicator light is green it indicates that the heater 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A is up to operating temperature and hot water is not being used It also indicates that the interior heating zones will op erate When the indicator light is off it indicates there is a demand for domestic hot water or the heater is not up to operating temperature and the interior hea
120. t reduces the diesel fuel into a fine spray which is mixed with incoming combustion air and is ignited within the combustion chamber In order to perform the following procedures it is necessary to detach and reattach the diesel burner head Be sure to review section 9 for detaching and reattaching instructions Fuel Nozzle Component Test 1 Follow the directions for detaching the diesel burner in section 9 of this manual 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A 2 Hook the diesel burner up to an alternate fuel source A Disconnect the steel fuel lines from the diesel burner B Install the fuel line bypass adapter fitting onto the diesel burner C Install rubber fuel lines on both the supply and return fuel pipes and install the other end of the rubber fuel lines into an adequate supply of diesel fuel Reference figure 3 Remove both the ignition cables from the ignition electrodes or connect a jumper wire with alligator clips across the metal tips of the electrodes A DANGER A Failure to connect a jumper wire across the ignition elec trodes or to remove the ignition cables from the ignition electrodes will result in a HIGH VOLTAGE shock and or a fire If the ignition cables are removed be sure to place a piece of electrical tape on the end of each cable 4 Remove the B plug from the diesel burner head s controller 5 Turn the diesel switch ON and t
121. t will not operate Low Tank Level Cutoff The Low Tank Level Cutoff senses the level of antifreeze in the boiler tank and will shut the Diesel Burner and the Elec tric Heating element OFF when the light illuminates red Under normal operating conditions this light will not be illuminated because an adequate level of antifreeze and water heating solution within the Aqua Hot s boiler tank exists When illuminated red only three possible issues exist the antifreeze and water heating solution level is inadequate and must be refilled there is a short in the wiring to the fluid level sensor or the fluid level sensor is not operating proper ly Heating Status This indicator light will illuminate green only when the diesel burner and or the electric heating element switch on the interior switch panel is on and the control thermostat is calling for heat If the heater is functioning and the light is not illuminated or the heater is not functioning and the light is illuminated there is an issue with the wiring or one of the components Engine Preheat Pump This indicator light shows the status of the engine preheat pump by illuminating green for on red for fault or by turn ing off when the engine preheat pump is not operating The system is functioning correctly when the indicator light is green while the engine preheat switch on the interior switch panel is on the electric element and or diesel burner switch is on
122. ter whenever a hot water faucet is opened such as with a shower or sink When hot water is requested domestic water from the motor home s fresh water tank is transported through a copper coil in the Aqua Hot s boiler tank where heat is transferred from the heated antifreeze and water heating solution to the do mestic water flowing through the copper coil The heated domestic water then flows through the tempering valve to be mixed with cool water from the fresh water tank to achieve an appropriate temperature before it flows to the faucet re questing hot water Page 6 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Engine Preheat System The engine preheat system is responsible for heating the mo tor home s engine block in order to make it easier to start up when cool weather conditions exist When the engine preheat system is activated via the interior switch panel the motor home s engine coolant is circulated through a dedicated copper coil in the Aqua Hot s boiler tank where heat from the antifreeze and water heating solu tion is transferred to the motor home s engine coolant The heated engine coolant is then transported back to the engine where it transfers the heat to the engine to gradually warm it Additionally the Aqua Hot 450 DE includes a motoraide feature which uses the circulation of the motor home s en gine to transport the engine s coolant from the Aqua Hot s boi
123. thermostat Page 23 Low Temperature Cutoff Thermostat The low temperature cutoff thermostat operates the domestic hot water priority system by blocking the interior heating feature when domestic hot water is being used This ensures that even heat is provided for domestic hot water which avoids the possibility of cold water pockets during showers etc Troubleshoot the low temperature cutoff thermostat if the following conditions have occurred e There is a lack of interior heat e There is a lack of hot water and the Low Temp Cutoff Status indicator light on the electronic controller con tinuously remains illuminated which does not allow the stir pump to operate Troubleshooting 1 Determine if the conditions are right for the Low Temp Cutoff Status indicator light on the electronic controller to be illuminated A Verify that the Aqua Hot is at operating temperature between 158 F and 190 F B Verify that the domestic hot water is not being used 2 Ifthe Low Temp Cutoff Status indicator light on the electronic controller is not illuminated after it has been determined that it should be complete the following A Install a jumper wire on the JP3 plug between pins 9 and 10 LTCO O and LTCO T on the elec tronic controller If the indicator light does not illuminate once the jumper wire is installed follow the instructions in this manual to replace the electronic cont
124. thick end of the punch at dead center Tap the punch lightly until the retaining clamp re turns to proper form 4 Using a 10 mm socket tighten the retaining clamp bolt 5 Remove the electrode adjustment gauge and reat tach to the diesel burner head Replacement Procedure 1 Using a 10mm socket loosen and remove the re taining clamp bolt and the retaining clamp 2 Slide the electrode out of the photo disc 3 To remove the electrode hold onto the orange elec trode boot and pull firmly on the electrode 4 Once the electrode has been removed Inspect inside the orange electrode boot for the retaining clip which holds the electrode in place If it is missing replace the electrode boot Electrode Adjustment Gauge Ignition Electrodes Electrode Adjustment Gauge Properly Positioned Fuel Nozzle Manifold 2009 Aqua Hot 450 D Hydronic Page 61 Heating System Service Manual Rev A SECTION 10 DIESEL BURNER COMPONENTS Ignition Electrodes Replacement Procedure continued 5 Insert the new electrode into the orange electrode boot and snap into place Pull firmly on the elec trode to make sure the retaining clip has secured the electrode in place Slide the electrode into the photo disc Install retaining clamp and retaining clamp bolt and finger tighten Follow steps 2 5 to properly adjust the electrodes Fuel Nozzle The fuel nozzle is simply a fuel atomizer I
125. tivity characteristics Although these types of antifreeze products are considered less toxic and safer than ethylene glycol for people pets and the environment they are not Generally Recognized as Safe GRAS rated by the FDA Therefore they must be marked with a harmful if swal lowed warning This additional warning is required be cause these types of antifreeze products contain high levels of chemical inhibitors Due to their potentially hazardous properties they should never be used in the Aqua Hot s Hydronic Heating System Antifreeze Mixture Water Quality In order to ensure maximum performance and longevity of an Aqua Hot heating system s boiler tank and associated components it has been determined that there is a need to use distilled de 10nized or soft water in combination with concentrated propylene glycol for the Aqua Hot s antifreeze and water heating solution Please note that this is only nec essary when mixing concentrated propylene glycol antifreeze with water suppliers of pre mixed antifreeze are responsible for the use of high quality distilled de ionized or soft wa ter when preparing their antifreeze for sale Hard water possesses a high level of calcium and magnesium ions which deplete the propylene glycol antifreeze s corro sion inhibitors This in turn causes the antifreeze and water heating solution to begin turning acidic which can corrode the Aqua Hot s boiler tank and associated co
126. tor and flange assembly along with the clutch halves Disconnect the motor s black and brown wires from the C plug harness wires Inspect the clutch halves for cracks and also ensure that the flat portion in each shaft hole is free of wear and tear Too much play on the shaft produc es a loud clacking noise If any cracks or wear are detected the clutch half must be replaced 4 Detach the motor from the motor flange by removing the two Phillips heads screws that fasten the two parts together 5 The motor must be mounted to the flange with the wires and drain hole pointing downward and the recessed edge of the motor flange pointing upward This will ensure a proper protection cap fit 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A NOTE Be sure to test the diesel burner s bearings prior to reinstalling the motor Worn bearings can cause 10 11 lower than normal RPM readings and premature motor wear Reinstall a clutch half on both the new motor s shaft and the combustion air blower shaft Attach the motor and flange assembly with the recessed edge of the motor flange in line with the wiring access slot of the blower casing to the blower housing with the three hex head screws Inspect the blower casing s O ring for damage or wear prior to reinstalling the diesel burner head s protection cap If damage or wear exists replace the O ring Connect the black and the br
127. tures is called the burst point Once the solution reaches the burst point the potential is present for ruptured pipes to ex ist The burst point of the antifreeze and water heating solu tion is dependent upon the brand of propylene glycol em ployed Boiling Point The Aqua Hot utilizes the antifreeze and water heating solu tion as a transportation means for the heat produced from the internal processes The antifreeze absorbs the heat created until its boiling point is reached it is at this point that the liquid turns to a gas and is expelled to prevent the heating system from overheating Each time the boiling point is reached a loss of efficiency occurs because the heat pro duced is expelled rather than used for the function of the heating system Therefore a higher boiling point is desired in order to combat the loss of efficiency which allows the antifreeze to transport the heat created from the internal pro cess throughout the motor home where it can be used pro ductively rather than dissipating due to its change from a liquid to a gas Rust and Anti Corrosive Inhibitors Another major function of antifreeze is to provide protection to the internal metal components of the Aqua Hot Hydronic heating system from corrosion and rust Antifreeze is able to perform this function by the addition of rust and anti corrosive inhibitors which are designed specifically to acti vate in a water solution Summary Antifree
128. ty a D C High Limit Thermostats 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 5 AQUA HOT COMPONENTS B Disconnect the wires from each thermostat and re check each thermostat for continuity as well as each of the thermostats individual wires If an individual wire does not have continuity that wire must be replaced If a thermostat with the wires removed that has been reset does not have continuity follow the instruc tions in this section to replace the high limit ther mostat NOTE If the high limit thermostats continue to trip trou bleshoot the control thermostat and verify the boiler tank is full of the antifreeze water solution Replacement Procedure A DANGER A FAILURE TO DISCONNECT ALL POWER SUPPLIES AND OR TO ALLOW THE HEATER TO COOL BEFORE SERVICING COULD CAUSE SERIOUS DAMAGE OR PERSONAL INJURY 1 Ensure that the Aqua Hot has been completely shut down and that all power sources have been disconnect ed 2 Remove the two wires from the defective high limit thermostat by pulling firmly on the wires 3 Using a 5 8 wrench or socket remove the defective high limit thermostat from the Aqua Hot s boiler tank 4 Install the replacement high limit thermostat into the port on the Aqua Hot s boiler tank and finger tighten only 15 in Ibs 5 Connect the wires removed from the defective high limit thermostat to the replacement high limit
129. u ENTUM HE ee Page 30 32 ss ore diem a sem M T m Em Page 33 34 Rem Cr a n Page 35 Section 6 Electronic Controller EE Eege Page 36 secondary 12 Volt DC battery Connection Page 37 Terminal Strips with Gcrew Tvpetastenerg Page 37 Low Voltage Reset Feature Page 38 R Dlacement PROCCOUNG PET Page 39 Proper Jurripsr PIN Gei A Le BEE Page 39 Page 3 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A B Table of Contents section 7 Electronic Controller Indicator Lights Electric Heating Element Status Indicator Light cccecccecceeeceeeceeeeeeeaeeeeeeseeseeeees Page 40 Heating Zones Status Indicator Lights 1 5 Page 40 LOW Balterv voltage Fault Indicator EIQUE E aec ouo pM reese ihe Page 40 Low Temp Cutoff Status Indicator Light Vs Page 40 Low Tank Level Cutolr e elteren EE Page 40 Heating Status INGICATON LIQNE uiii cia eee den sn ease tee xa o iue nn e e iae Page 40 Engime Premneasbri umpndicator BIoiba soient oi tatu iua ot to Re e ne Page 40 Cireulation Pump 7 1 Indicator len EE Page 41 Circulation Pump 2 Indicator Light Page 41 Sur Pump 3 Indicatot LIO socii tiara aad etui iti e Eat annees Page 41 Diesel Burner Status Indicator Elghl ui e ee een dan neun SEU REUS Page 41 Overload Faulbtirdicator D Le ln EE Page 41 Section 8 Diesel Burner KEE Page 42 HO E EE Page 42 Diesel B rner OVervIQW vue inert ioo iai aei re
130. ubber Grommets g Snap Retaining Ring Flat Drive Nut Washer Gear Thick Steel Page 70 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 10 DIESEL BURNER COMPONENTS Ignition Coil 3 Connect the ignition coil wires directly to a 12 volt DC power supply i e black wire to lead and The ignition coil produces a high voltage ignition brown wire to lead spark approx 8000 volts which is released across the metal tips of the ignition electrodes during the 4 Turn the power supply ON and watch for a spark to initial diesel burner start up appear across the metal tips of the ignition elec trodes If a spark does not appear the ignition coil Use extreme care when testing the ignition coil as a High must be replaced Voltage Shock may result NOTE Some ignition coils are intermittent and will need NOTE In order to perform the following procedures it is to be tested numerously necessary to detach and reattach the diesel burner head Be sure to review the section for detaching and reattaching the diesel burner Component Test Before replacing the ignition coil 1 Verify the ignition electrodes are not cracked or broken Verify that the ignition electrodes are adjusted properly Ensure the electrode boots are securely holding the electrodes in place Ensure the electrode boots are not broken inside the igni t
131. y be necessary to perform a voltage check to ensure that this condition exists To perform the voltage check locate the diesel burner controller s B plug and insert the probes of a DC voltmeter into the B 1 and B 2 locations Turn the diesel switch ON and observe the voltage level Ground Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the B 4 and C 5 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test VDC VAC Control Thermostat Circuit Test 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the C 1 and B 2 locations and turn the diesel switch ON If a voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test VDC High Limit Thermostat Circuit Test Locate the diesel burner controller s B plug and C plug Insert the probes of a DC voltmeter into the C 4 and B 2 locations and turn the diesel switch ON Ifa voltage reading does not register on the voltmeter the diesel burner controller must be replaced If voltage is present proceed to the next circuit test Mot
132. ze has three basic functions freeze protection boil over protection and anti corrosion and rust protection 2009 Aqua Hot 450 D Hydronic Heating System Service Manual Rev A SECTION 2 AQUA HoT 450 DE OVERVIEW Antifreeze is also primarily responsible for heat transfer characteristics Therefore as water is an excellent heat con ductor it is added to the mixture A 50 50 solution of pro pylene glycol antifreeze and water is recommended to pro vide the best performance combination of the aforemen tioned functions If excess propylene glycol exists within an antifreeze and water heating solution the water s heat ab sorption properties are compromised which could ultimately inhibit the Aqua Hot from providing adequate domestic hot water and interior heating Additionally if the antifreeze and water heating solution contains over 70 percent antifreeze the freezing point is ac tually raised resulting in less freeze protection Page 14 The interior switch panel is used to control the two potential heating sources for the Aqua Hot s boiler tank as well as to control the engine preheat feature When a switch is activat ed the indicator light on the switch will illuminate Diesel Burner Switch When the diesel burner switch is in the on position any time the control thermostat tells the electronic controller that heat is needed for the boiler tank the diesel burner will respond by firing up and providi

SERVICE MANUAL AHE-450-DE2 - Aqua

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